Poultry litter-based fertilizer and a method for making the poultry litter-based fertilizer from poultry litter

ABSTRACT

A method for producing a poultry litter-based fertilizer by a) supplying poultry litter to a rotating rotary drum, b) adding acid or a source of acid to the rotating rotary drum, wherein acid reacts with the poultry litter to form an acidified mixture, c) adding ammonia or a source of ammonia to the rotating rotary drum, d) drying and cooling the ammoniated product by evaporation of water to form a dried, cooled product in a free-flowing semi-solid or solid form, repeating the steps b) through d) until a desired nitrogen content is reached in the dried, cooled product.

FIELD OF THE INVENTION

The present invention relates to a new and improved poultry litter-basedfertilizer and method for the conversion of poultry litter into avaluable poultry litter-based fertilizer containing enhanced levels ofnitrogen, sulfur, secondary nutrients, and micronutrients, an elevatednitrogen to phosphorus ratio, and organic carbon to improve soil health.The process to produce the poultry litter-based fertilizer isenvironmentally friendly in that it does not require added heat fromburning fossil fuels, produces clean air emissions, and does not releasesignificant quantities of carbon dioxide or other greenhouse gases.Off-gases and dust as well as any waste streams from the process arerecycled back into the process. The only main discharges from themethods are water vapor and the poultry litter-based fertilizer product.

BACKGROUND OF THE INVENTION

Many million tons of poultry litter are produced annually in the UnitedStates virtually all from intensive systems. Poultry litter is solidwaste material composed primarily of bedding material (any of a varietyof lignocellulose materials), feathers, spilled animal feed, and poultryexcreta, the litter having been removed from poultry houses. Therelative proportion of bedding to excreta can vary widely, as can thechemical nature of the litter. There also may be pathogens, weed seed,and drug contaminants present in the litter. Litter is, of course,malodorous due to various odorants or precursors thereof. In addition tofree ammonia there have been identified odorants such as mercaptans,sulfides, di-ketones, indole, and skatole. Litter contains and duringstorage and composting generates many volatile organic compounds (VOCs).

Poultry litter is recognized as a serious source of nitrification ofwaters. As poultry production steadily grows due to demand for poultryproducts and population growth; so does the waste from this production.Efforts to protect our environment have led to regulations causing localproducer/farmers to struggle with meeting state mandated nutrientmanagement program requirements while remaining solvent with narrowprofit margins.

Currently, the U.S. alone generates 13 million tons of poultry littereach year. The growing population consuming more poultry also needs anincreasing food supply from crops which require fertilizer. Poultrylitter is used as fertilizer due to its well-documented source ofprimary plant nutrients (nitrogen, phosphorus, and potassium), secondarynutrients (sulfur, magnesium, and calcium), and micronutrients likezinc, copper, iron, boron, nickel, manganese, and molybdenum. However,using poultry litter as a fertilizer in either its raw form or aftertraditional treatments like composting or rotary drum heat treatment isnot nutrient efficient, energy efficient, or safe to our health orenvironment. Also, even litter that has been heat treated will give offoffensive odors when exposed to moisture or rain. Additionally, litterhaulers are faced with a growing supply of poultry litter and anarrowing availability for land application. This leads to stockpiles oflitter that further cause problems from release of greenhouse gases,potential leaching and run-off, human and animal exposure to pathogens,and loss of nutrients in the litter.

Animal production concentrated in small regions has led to litterdisposal problems causing growing health and environmental issues, bothinternationally and in the U.S. According to the USDA ERS, 69% of thebroilers produced in the U.S. were produced in the southern states ofGeorgia, Arkansas, Alabama, Mississippi, North Carolina, Texas, andKentucky. Currently, poultry litter management regulations requirepoultry producers to create nutrient management plans that include safedisposal and use of their litter waste. These regulations put aconsiderable burden of management on the shoulders of local farmers whoalready face tough profit margins. Currently, most poultry litter isapplied to fields. However, this use of litter is inefficient, bad forthe environment, and a threat to human health. Furthermore, farmers faceregulations on land application that restrict when litter can beapplied. The concentration of litter production to certain regionscombined with the regulations on land application have created an excessof litter with no place to apply it. This leads to a need for safe usesof the litter, especially in times when land application is controlledor banned.

One way that poultry litter is a threat to our environment is in landapplying it in raw form. This practice has been shown to lead to runoffto waterways and leaching to groundwater leading to nitrification ofwaterways. This is especially true when phosphorus builds up in the soildue to repeated applications of poultry litter. The leaching ofphosphate from the soil is a serious problem in major waterways such asis seen currently in the Chesapeake Bay.

Poultry litter is typically 3-3-3 (% N-% P₂O₅-% K₂O), on averagetypically contains 20-30% moisture and 25-35% organic carbon. Sinceplants have a much higher need for nitrogen than for phosphorus, litteris added at higher levels than the plants are able to take upphosphorus. As a result, with repeated applications of litter,phosphorus builds up in the soil which has led to regulations now inplace to limit the land application of litter in areas with highphosphorus or areas close to waterways.

Poultry producers often use lime to control disease in their poultryhouses. As a result, litter from these producers may be high in calcium.When this litter is applied, calcium levels in the soil increases aswell as the soil pH. Over time, this inhibits the uptake of othernutrients such as magnesium and zinc.

Poultry litter poses human health problems in various ways. Untreatedlitter dust not only smells bad but also carries pathogens in the airthat can be dangerous to humans. These pathogens also have potential tobe transmitted to livestock feeding on grass in fields treated withlitter as well as to vegetables and other crops grown with litter usedas fertilizer. Typical methods of mitigating this problem includecomposting or stacking the litter. These methods allow heat to kill thepathogens before applying.

However, pathogens may persist due to uneven heating during the processand not only survive but become even more virulent than prior to thetreatment. Food can then be contaminated when grown with the treatedlitter.

Another health concern of using litter is the existence of drugs andhormones in the litter. The presence of antibiotics in our environmentas well as other drugs has become an increasing concern to human health.Not only can these enter the water supply; but in the case ofantibiotics, they can increase the virulence of bacteria in ourenvironment.

Composting and stacking litter has an additional negative effect on ourenvironment which is the release gases and reduced air quality. Asstated above, pathogens can be transmitted to air by poultry litter.Composting litter also causes losses of both nitrogen and phosphorus dueto denitrification and ammonia volatilization, run-off, and leaching.These losses can be quite high.

Another method of treating poultry litter to create a product forfertilizer is rotary drum drying. This uses heat to kill harmfulorganisms and heats the product more evenly. However, it requires theuse of fossil fuels, is inefficient, and suffers from nutrient loss, inparticular nitrogen, as well as the generation of greenhouse gases.Also, when the litter encounters moisture; offensive odors aregenerated.

Canadian Patent No. 1214062 (Anthony, Smith, and Shirley) discloses aprocess of producing fertilizer from poultry litter, the completedisclosure of which is incorporated herein by reference. However, thisprocess is limited in the amount of nitrogen in the final fertilizerproduct. The present invention is a substantial and surprisingimprovement over this patent.

U.S. Pat. No. 4,650,682 (Shirley, Jr.) illustrates a preferred type ofacidifier-ammoniator vessel that can be modified as described herein foruse in the present process. The complete disclosure of this patent isincorporated herein by reference.

There is a great need for a clean, non-polluting, poultry litter-basedfertilizer that is free of offensive odors and has an increased level ofnitrogen. Such a clean poultry litter-based fertilizer would providebenefits to plants due to its nutrient content as well as its ability toimprove soil health. Arable land is decreasing and one of the causes ofloss of arable land is a depletion in organic carbon. Poultry littercontains organic carbon; and when this litter is land applied, leads toan increase in soil carbon that improves the water holding capacity ofsoil. Using a clean poultry litter-based fertilizer on land would helpto reverse damage from long term cultivation by improving formation ofsoil aggregates which improves water and oxygen diffusion rates.

Poultry litter is typically comprised of 30% bedding material and 70%excreta. As a result, the litter is a complex mixture of many compoundsincluding sugars, fatty acids, cellulose, lignin and extractives,vitamins, and amino acids. Poultry litter naturally contains all of thenutrients, secondary nutrients, and micronutrients needed by plantsincluding N, P, K, S, Zn, Ca, Mg, Mn, B, and Cu. The nutrient content oflitter depends on many factors including management practices, the typeof bedding material used, feeds, and more. Typically, on a dry basispoultry litter contains 1%-4% N, 25%-35% carbon, 1.4%-6.6% P₂O₅,1.3%-4.1% K₂O and 0.3% to 2% S. Poultry litter also contains high levelsof lignocellulose due to the bedding materials used in poultry houses.The bedding materials used are readily available forest and agriculturalwastes such as straw, wood chips, peanut hulls, and rice hulls, forexample. Poultry litter differs significantly from other wastes used toproduce fertilizer. Poultry litter contains a multiplicity of organiccompounds in addition to lignocellulose and these differ from organiccompounds in manures, sewage, and biosolids.

It is well known that ammonium nitrate is explosive. According to theUnited States Department of Homeland Security, the minimum detonablelevel of ammonium nitrate is 10% (DHS Ammonium Nitrate Security Program,Vol. 84 No. 106, Fed. Reg. 25495, Jun. 3, 2019).

SUMMARY OF THE INVENTION

The present invention converts poultry litter to a valuable dry,homogenous balanced granular or pelletized fertilizer free of noxiousodors, free of harmful pathogens and viruses, free of viable weed seeds,and free of drugs, steroids, and pesticides. The process to convertpoultry litter to fertilizer uses only a rotary drum. No dryer using anoutside source of fuel such as fossils fuels or burning of organicmatter is required such as is required in Canadian Patent No. 1214062(Anthony, Smith, and Shirley). This process is accomplished byrepeatedly treating the poultry litter with a strong acid acidifyingstep followed by a partial neutralizing and ammoniating step withcarefully controlled addition of water, followed by an evaporativedrying and cooling step. The drying and cooling step can be accomplishedwhile controlling temperature and removing moisture volatilizedutilizing the heat generated by the acidifying and the ammoniating stepsto thereby convert the poultry litter to a dry free flowing granularfertilizer product or to a pelletized fertilizer product. The ability toproduce a dry granular fertilizer product with elevated nitrogen usingthe heat of the process is a surprising and significant improvement overprevious processes to convert poultry litter to fertilizer or animalfeed.

Surprisingly, by adding water during the process; the inventionunexpectedly allows for the production of a granular product withsignificantly more nitrogen than would be expected. This addition ofwater is counterintuitive for producing a dry product but necessary inorder to cool the product and to react acid in the interior of thegranule with base applied after acidifying the litter. In a rotary drumprocess that produces granular ammonium sulfate, ammonium sulfatecrystallizes on the surface of the material as ammonia and acid react.Ammonium sulfate crystallizing on the surface of the material as it isbeing made prevents the reaction of ammonia with acid in the interior ofthe material. The present invention surprisingly overcomes this problemby strategically adding water just before and/or during addition ofammonia to keep the ammonium sulfate solubilized on the surface of thegranule. The addition of water dissolves ammonium sulfate formed on thesurface of the granule and allows the penetration of ammonia into thegranule to react with sulfuric acid which is otherwise trapped beneath alayer of crystallized ammonium sulfate. This novel solution solves amajor unexpected problem and results in a dramatic increase in nitrogencontent of the fertilizer. As a result, the formation of ammoniumsulfate is throughout the whole granule which allows the reaction ofsignificantly more ammonia with acid resulting in a granular productwith higher nitrogen levels and less free acid. By adding an evaporativedrying and its accompanying cooling step in the rotary drum afterammoniating and then repeating acidifying and then ammoniating whileadding water, the nitrogen level of the product can be increasedfurther. Without the evaporative drying and cooling step, the processreaction temperature could not be controlled and would resultundesirable clumping of the material and prevent production of agranular product of the controlled desired size.

Due to the high levels of heat generated by dilution of concentratedacid and the reaction of the acid with ammonia, the final product is adry granule without the use of fossil fuels or the burning of organicmaterials to dry the product. By carefully controlling the addition ofwater to the process and by using an evaporative drying and coolingstep; the final product contains a desired target moisture level and isa 1 mm to 3 mm granule. This size range of granules is an ideal size foragricultural fertilizer, golf courses, and lawns.

The present invention provides unexpected and surprising advantages overthe prior poultry litter-based fertilizer methods. The present poultrylitter-based fertilizer product contains significantly higher levels ofnitrogen than typically contained in poultry litter; and the ratio ofnitrogen to phosphorus is significantly increased, thereby dramaticallyreducing the land application of phosphorus and thus pollution runoff ofphosphorus into waterways, bays, and gulfs is also radically reduced. Inaddition to the increase in nitrogen, the sulfur levels are alsosignificantly increased. The final fertilizer product no longer producesan offensive odor even if it is exposed to moisture since the compoundscausing the odor are altered by the present process.

The nitrogen in the present poultry litter-based fertilizer product canbe a combination of slow release and quick release and includes nitrogenpresent in the starting litter. If desired, micronutrients in the finalproduct are enhanced by the process to levels to meet plant requirementsand to allow uptake by plants. The fertilizer also contains organiccarbon to improve soil health. By adjusting the pH and heat; pathogens,viruses, weed seeds, drugs, hormones, steroids, and antibiotics aredestroyed. All of this can be accomplished without burning fossil fuelsto heat the material or to dry the material and all waste streams arerecycled back into the process. Thus, only water vapor and the finalfertilizer product are expelled from the process.

During the processing of the poultry litter, nitrogen content of theexcreta component of the litter is stabilized by converting volatile orpotentially volatile nitrogen compounds in the excreta to a non-volatileform. This stabilizes the nitrogen compounds so that nitrogen in thestarting poultry litter is retained in the product rather thanvolatilizing and the nitrogen compounds do not produce odor even if theproduct is exposed to moisture. In the process, the reaction conditionsin the steps are selected and controlled so that heat generated by thechemical reactions (heat of dilution of acid, heat of reaction of acidwith the litter, and subsequent heat of reaction of ammonia withacidified litter) raises the temperature and reduces the pH to levels atwhich the pathogens, drug contaminants, and weed seeds are destroyed orrendered non-toxic. The acidifying step reaches such a low pH that bondsin organic compounds are reacted changing the chemical makeup of thelitter and destroying viruses, pathogens, drugs, steroids, VOCs, andother compounds present. These reactions are not reversible and thus theorganic compounds remain in their changed form as new chemicals.

The material enters an evaporative drying and cooling step in theprocess during which the product is cooled and water is removed. Thisevaporative drying and cooling step must occur before repeating theacidifying and ammoniating steps to keep the material free-flowing sincethe ammonium salts produced are soluble in water. The process results ina dry or essentially dry product without direct input of heat.

In one embodiment of the invention, the litter enters aReactor-Evaporator Drum disclosed in U.S. Pat. No. 4,650,682 (Shirley,Jr.), and has been modified to comprise multiple zones as shown in FIG.7, where the first step is an acidifying step using an acid or acombination of acids chosen from the group comprising sulfuric acid(H₂SO₄), sulfurous acid (H₂SO₃), nitric acid (HNO₃), nitrous acid(HNO₂), phosphoric acid (H₃PO₄), phosphorous acid (H₃PO₃),hypophosphorus acid (H₃PO₂), pyrophosphoric acid H₄P₂O₇, triphosphoricacid (H₅P₃O₁₀), trimetaphosphoric acid (H₃P₃O₉), and hypophosphoric acid(H₄P₂O₆), boric acid, organic acids like acetic acid, citric acid forexample, and other acids. Preferably, the acid or source of acid used isa strong acid or forms a strong acid, such as 93-98% sulfuric acidand/or oleum, more preferably 98% sulfuric acid or oleum. When nitricacid or nitrous acid are used, they are used at levels to keep theresulting ammonium nitrate level in the product at less than 10% to keepit below the minimum detonable level. Thereafter the ammoniating stepuses ammonia to react with the acid and/or acids and produces anammonium salt or ammonium salts and heat. Just before and/or during theammoniating step, water is added to the material to solubilize theammonium sulfate as it forms on the surface of the material and allowthe ammonia to react with the sulfuric acid in the material. Next, thematerial enters an evaporative drying and cooling step during which heatis removed by the evaporation of water in the material. The acidifying,ammoniating with water, and drying and cooling steps are repeatedsequentially to further increase the nitrogen in the material and thenthe material enters a final evaporative drying and cooling step toremove moisture and heat. The drying of the material is accomplishedwithout the use of an expensive dryer supplied with heat by burninglitter, burning fossil fuels, or using other heat sources from outsideof the rotary drum process.

During the final evaporative drying and cooling step, wash down watercan be sprayed to further cool the material and/or a waste streams canbe sprayed to further cool the material and recycle the waste stream. Ifnecessary, additional water is sprayed to further cool the material.This results in a dry or essentially dry product without direct input ofheat.

During the process, in particular during the acidification step, thematerial agglomerates into granular particles on being sprayed with acidwhile moving in the fastest portion of the rolling bed in the rotarydrum. During this spraying, physical attraction between small particlesand acid is at a level that allows the formation of granules. As shownin the examples, it is important to spray and not stream the acid inorder to control the granule size.

In a preferred embodiment of the invention, granular fertilizer isproduced in a rotary drum. Agglomeration occurs in the acidifying step.Water is added before and/or during the ammoniating step to dissolveammonium sulfate as it forms, to cool the product by evaporation ofwater, and to capture and distribute the ammonia that is sparged intothe rolling bed of solid material so that the reaction between ammoniaand sulfuric acid occurs throughout the whole granule. Without theaddition of water, the reaction occurs only on the surface of thegranule and the center of the granule contains concentrated sulfuricacid.

To elevate nitrogen levels to desired levels, the evaporative drying andcooling step is necessary to keep the material free flowing in a solidor semi-solid form. This is due to the fact that acids react withammonia to produce ammonium salts such as ammonium sulfate, and theseammonium salts are very soluble in water. The pre-processed poultrylitter fed to the process can contain large amounts of water, forexample 20-40 wt. %, and this water dissolves the ammonium salt as it isbeing produced. To maintain the material as a free-flowing semi-solid orsolid, the resulting ammonium salt solution must be managed and thewater evaporated before more ammonium salt can be produced. Hence, wateris carefully added during the ammoniation step to form granules, tomaintain free flow and at the same time to keep the ammonium salt fromcrystallizing on the surface during the reaction of ammonia with acid asthe granule is formed so that high levels of unreacted acid do not gettrapped beneath the surface of the granule.

In a preferred embodiment of the invention, the material enters theReactor-Evaporator Drum where the acidifying step utilizes oleum (sulfurtrioxide dissolved in sulfuric acid) or a combination of oleum withother acids or sulfur trioxide gas injected into the bed in the samemanner as the ammonia is injected in the ammoniating step. During thisacidifying step, the sulfur trioxide reacts with water in the poultrylitter to form sulfuric acid. The reaction of sulfur trioxide with watermeans that less water must be vaporized by the heat of dilution and heatof reaction and therefore allows the addition of more water from othersources such as wash down water or alternatively the use of higherlevels of other acids with lower heats of reaction. The resultingproduct has a higher nitrogen to phosphorus ratio but a lower sulfur tonitrogen ratio than produced by using acids only. For this embodiment ofthe invention, after the acidifying step; either ammonia as well aswater and/or ammonium hydroxide is used for the ammoniating step toproduce an ammonium salt and heat. Next, the material enters anevaporative cooling step during which heat is removed by the evaporationof water in the material utilizing the heats of reaction. If necessary,water is sprayed to further cool the material by evaporation. Theacidifying and ammoniating steps are repeated sequentially to furtherincrease the nitrogen in the material to a desired level and then thematerial enters a final evaporative cooling step to remove moisture andheat.

In another embodiment of the invention, the material enters aReactor-Evaporator Drum where the acidifying step uses sulfuric acid ora combination of sulfuric acid with other acids and sulfur trioxideadded into the bed of litter in the drum. During this acidifying step,the sulfur trioxide reacts with water in the poultry litter to formsulfuric acid. After the acidifying step, either ammonia and waterand/or a source of ammonia, such as, ammonium hydroxide is used for theammoniating step to produce ammonium salt or ammonium salts and heat.Next, the material enters an evaporative drying and cooling step duringwhich heat and water are removed by the evaporation of water in thematerial. If necessary, water is sprayed to further cool the material.The acidifying and ammoniating steps are repeated sequentially tofurther increase the nitrogen in the material to a desired level, andthen the material enters a final evaporative cooling step to removemoisture and heat.

Sulfuric acid and/or oleum and sulfur trioxide partially carbonize thepoultry litter and/or convert the lignocellulose to sugars, and convertthe lignocellulose to forms of carbon more readily available to soilorganisms and plants.

In another embodiment of the invention, secondary nutrients and/ormicronutrients are enhanced in the fertilizer product by adding to theacidifying section of the Reactor-Evaporator Drum one or more metalschosen from the group zinc, iron, copper, magnesium, manganese, nickel,and more; and/or metal oxides chosen from the group zinc oxide (ZnO),magnesium oxide (MgO), manganese oxides (MnO, Mn₃O₄, Mn₂O₃, Mn₃O₄, MnO₂,MnO₃, Mn₂O₇), and copper oxides (Cu₂O, CuO, CuO₂, Cu₂O₃), iron oxides(FeO, FeO₂ and others), nickel oxide (NiO or Ni₂O₃), and others; and/ora combination of metals and/or metal oxides. These metals and/or metaloxides react during the acidifying step to produce soluble salts such assulfates for example that provide secondary and micronutrients in aplant-available form. In some cases, it may be desirable to add selectnutrients, secondary nutrients, and/or micronutrients as salts bychoosing one or more from the group lime, magnesium chloride, magnesiumnitrate, sodium nitrate, sodium chloride, zinc chloride, zinc nitrate,copper chloride, copper nitrate, potassium chloride, potassium nitrate,potassium sulfate, triple super phosphate, super phosphate, and others.When a nitrate salt is used, the nitrate salt may react to produce ametal sulfate and ammonium nitrate. Therefore, the level of nitrate saltused is such that the resulting ammonium nitrate is less than 10% byweight of the product in order to keep the ammonium nitrate below theminimum detonable level.

In another embodiment of the invention, nutrients, secondary nutrientsand/or micronutrients are enhanced in the fertilizer product by addingto the ammoniating section or sections of the Reactor-Evaporator Drumammonia and water and/or ammonium hydroxide in combination with otherbases chosen from the group potassium hydroxide, zinc hydroxide,magnesium hydroxide, manganese hydroxide, and other bases with elementsbeneficial to plants.

Phosphorus may be enhanced in the fertilizer product produced by theprocess by adding ground phosphate rock or phosphoric acid in theacidifying step and/or ammoniating step.

The current invention, converts poultry litter to a poultry litter-basedfertilizer that contains % N levels greater than 6%, more preferablygreater than 8%, and most preferably greater than 10%; with % P₂O₅levels of less than 3%, more preferably less than 2%, and mostpreferably less than 1.5%; with % K₂O of preferably more than 1%, morepreferably greater than 2% and most preferably greater than 3% which isadjusted by adding potassium hydroxide, potassium chloride, and/orpotassium sulfate, and/or other potassium source; and with % S levels ofgreater 2%, more preferably greater than 5% and most preferably greaterthan 7%. In reference to this document, all percentages are inconcentrations found as the percent by weight of the component comparedto the total weight of the material.

The starting poultry litter used in the present invention is a solidmaterial typically with 20%-30% water such that heats of reaction willbe capable of driving off water without the use of fossil fuels. On adry basis, the poultry litter is comprised of at least 2.5% nitrogen,and preferably at least 3.5% nitrogen; at least 3% P₂O₅; at least 2.5%K₂O, at least 1% sulfur; and at least 3.5% other secondary nutrients andmicronutrients.

Micronutrients occur naturally in poultry litter but can be enhanced asneeded using the inventive process which further provides micronutrientsin plant-available soluble form. The resulting poultry litter-basedfertilizer is a homogenous granular fertilizer in a free-flowingsemi-solid or solid form. The fertilizer's homogeneity allows themicronutrients to be applied uniformly over the field at low levels.Homogeneity of macronutrients is not easily achievable when applyingmicronutrients individually as granular material or as part of a blendedfertilizer. The present invention solves this problem by blending in anyadded micronutrients during the process of producing the poultrylitter-based fertilizer.

At least 10% of the inventive fertilizer product is comprised ofcompounds from the original poultry litter, preferably at least 20% andmore preferably at least 30% of the inventive product is comprised ofcompounds from the original organic materials measured on a dry basis.The organic carbon content of the poultry litter can still be present inthe product after the inventive process. This organic carbon in theproduct is preferably up to 35 wt % and more preferably 10 wt % to 30 wt% of the final poultry litter-based fertilizer. The starting nitrogenand other nutrients in the poultry litter is fully contained in theinventive fertilizer product.

For the process to control emissions and to produce enough heat toevaporate water without using external heat sources for drying, up to55% of the product can be from the starting litter. If desired, morethan 55% of starting litter can be in the final product and an outsideheat source used for drying the product. With these higher levels ofstarting litter in the product, the emissions will be only water vaporand the combustion products of the heat source.

All embodiments of the invention provide a process for treating rawpoultry litter in dry, particulate, free-flowing form comprising forminga stream of the free-flowing litter particles; spraying the stream withatomized acid or acid gas or adding the acid in an amount to reduce thepH of the particles to a level of less than 2.5, and preferably lessthan 2.0, and most preferably less than 1.0 in the first acid reactionstep; which destroys drugs, pathogens, viruses, steroids, hormones, andVOCs. The acid is added at a rate that maintains the acidified particlesas free-flowing or as flowing agglomerated particles and forming atumbling bed of the acidified particles or agglomerates; introducinganhydrous ammonia or aqueous ammonia into the acidified particles fromat least one location within the bed to increase the pH of the particlesto enhance the nitrogen content and to thereby generate heat andincrease the temperature of the particles to vaporize moisture, and tofurther reduce and destroy any residual pathogen content, render weedseeds non-viable, and destroy drugs; utilizing the heats of reaction anddilution and evaporative cooling to maintain a free-flowing material byremoving moisture and heat from the process before repeating theacidifying and ammoniating steps.

In one embodiment of the invention, during the acidification step theacidified material comprises preferably less than 35 wt. % water andmore preferably less than 30%.

In the drying and cooling step, the ammoniated material is dried byevaporation of water to a moisture content where the dried, cooledproduct is a free-flowing semi-solid or solid. The moisture content ofthe material at the end of the drying and cooling step is preferablyless than 20 wt. %, more preferably less than 15 wt. %, more preferablyless than 10 wt. %, and most preferably less than 5 wt. %.

The present invention can utilize the heat of reaction from sulfuricacid as it dissociates in water (heat of dilution) according to equation(1). This water is present in the starting poultry litter as well asadded during the process, especially in the ammoniating step.H₂SO₄→2H⁺+SO₄ ⁻+heat  (1)

Additionally, in the present invention sulfuric acid reacts with ammoniato produce ammonium sulfate through an exothermic reaction (see equation2). Ammonium sulfate is very soluble in water and it useful as afertilizer due to both its nitrogen and its sulfur content.H₂SO₄+2NH₃→(NH₄)₂SO₄+heat  (2)

The present invention can further utilize the heat of reaction whenacids react with bases to produce salts and water. One such reaction isthe reaction of sulfuric acid with ammonium hydroxide (aqueous ammonia)to produce ammonium sulfate as shown in equation (3).H₂SO₄+2NH₄OH→(NH₄)₂SO₄+2H₂O+heat  (3)

Other acid-ammonia reactions are useful in producing fertilizeraccording to the present invention and are exothermic, such as equations(4) for example.H₃PO₄+3NH₃→(NH₄)₃PO₄+heat  (4)

Metals in general react with acids to produce metal salts and hydrogen.Specifically, metals can react with sulfuric acid to produce metalsulfates and hydrogen gas as shown in equation 5 for example.Zn+H₂SO₄→ZnSO₄+H₂  (5)

Metal oxides can also be used to produce metal sulfates according toequation (6) for example.ZnO+H₂SO₄→ZnSO₄+H₂O  (6)

Sulfuric acid is known to react with double bonds in organic compoundssuch as aromatics, alkenes, sugars, cellulose, and more and results inan organic compound bound to a hydrogen sulfate group as illustrated byone simple example reaction shown in Equation 7 below.CH₂=CH₂+H₂SO₄→CH₃—CH₂HSO₄  (7)

Oleum, also called fuming sulfuric acid (H₂SO₄.xSO₃), is a solution ofsulfur trioxide in sulfuric acid that is beneficial to soil organismsand that enhance plant growth. Sulfur trioxide reacts with water to formsulfuric acid according to equation (8).SO₃+H₂O→H₂SO₄+heat  (8)

Hence, oleum uses up water when it reacts as well as releases heatduring the reaction. Furthermore, both sulfuric acid and oleum are knownto hydrolyze lignocellulose to sugar. Sulfuric acid and oleum maydehydrate sugar to produce carbon. Oleum is an example of source of acidthat can convert to acid in the vessel.

Rotary Drums having multiple zones can be constructed for use in theacidifying operation, ammoniating operation, and the evaporative coolingoperation as the vessel, herein referred to as a Reactor-EvaporatorDrum. The Reactor-Evaporator Drum preferably includes at least threeseparated chambers (also referred to as zones), which are separated bybaffles, and the chambers are in communication with each other so thatthe materials can flow from one chamber to the next in a continuousmanner to operate the entire process in a continuous manner. The rotarydrum can include multiple zones, such as six in total as shown in theFIGS. 1A, 1B and 7. However, any desired number of zones can beutilized, such as 5, 8, and 9 zones may also be used, separated bybaffles. Each zone is designed to optimize the process for that zone.The first zone of the six zone drum is the acidifying zone. In thiszone, the acid and/or source of acid is added to the litter so that thematerial remains free flowing. The next zone is where the ammonia and/orsource of ammonia is added so that the ammoniating takes place and isdownstream from the acidifying zone. In the ammoniating zone, preferablyanhydrous ammonia and water is added or ammonium hydroxide (a source ofammonia) which reacts with the acidified material produced in the firstzone. In both the first and second zone, heat is generated so that thetemperature of the material is increased preferably to greater than65.6° C. (150° F.), more preferably greater than 82.2° C. (180° F.),more preferably greater than 90° C. (194° F.), and most preferablygreater than 98.9° C. (210° F.).

Next is the evaporative cooling zone of the rotary Reactor-EvaporatorDrum which uses lifting flights to lift the material and create fallingmaterial that falls through the cross-section of the evaporative coolingzone of the Reactor-Evaporator Drum. Thus, free-flowing means thatsemi-solid or solid particles of the material can remain separated fromone another during the process so that the semi-solid or solid particlescan fall during the process. This allows maximum contact of the materialwith air that can be continuously pulled or pushed through the zones ofthe Reactor-Evaporator Drum and thereby maximizes the heat and waterremoval from the material in the drum.

If necessary, water and/or wash water may be sprayed in the evaporativecooling zone. Wash water is water from washing down plant floors andequipment. Once the material has cooled to less than 80° C. (176° F.),more preferably to less than 76.7° C. (170° F.), more preferably to lessthan 71.1° C. (160° F.), and most preferably to less than 65.6° C. (150°F.); the material enters the next zone of the Reactor-Evaporator Drumwhich is another acidifying zone as described previously. Then thematerial passes to another ammoniating zone, and finally to the finalevaporative drying and cooling zone both of which are as describedpreviously. The poultry liter-based fertilizer leaving the drumpreferably has a moisture content of less than 12%, more preferably lessthan 10%, and most preferably less than 8% water.

Alternatively, the Reactor-Evaporator drum may be modified to have ninezones with the first six as described above and the last three being anadditional acidifier zone followed by an ammoniating zone followed by anevaporative cooling zone. As another alternative if desired, theReactor-Evaporator may be designed with either five zones or eight zoneseliminating the last evaporative cooling zone from the six zone or ninezone Reactor-Evaporator Drums respectively. In the case of the five zoneand eight zone drums, the final evaporative cooling step when needed isperformed in a separate drum, a fluid bed, or other drying and coolingtechnology known to those familiar in the art of drying and coolingmaterial.

The Reactor-Evaporator Drum can be continually swept with air. Theseoff-gases can be sent to a scrubber to be scrubbed with acid, preferablysulfuric acid. The drum, scrubber, and ductwork through which the moistair passes are insulated to reduce loss of heat to the surroundingenvironment and prevent water from condensing in the drum, ductwork, andscrubber. The scrubber solution can be recycled back into the process,for example added with the acid in the acidifying step. Wash down watercan also added back into the process preferably prior to or with theacidifying step, and/or with the ammoniating step, and/or in theevaporative cooling step; most preferably in the second ammoniating stepand/or evaporative cooling step. It is preferable not to add scrubbersolution to the final evaporating step since this solution containssulfuric acid and could produce a final product that is too acidic.

An alternative embodiment of the invention includes using two or morerotary drums each with three sequential zones: an acidifying zonefollowed by an ammoniating zone followed by an evaporative cooling zone.

Another embodiment of the process uses a drum with only three sequentialzones: acidifying, ammoniating, and evaporative cooling; and thenrecycling a portion of the material back into the drum.

For all of the above embodiments, once the processed litter has reachedthe targeted % N of preferably more than 6%, more preferably more than8%, and most preferably more than 10%; and the percent moisture ispreferably less than 12%, more preferably less than 10%, and mostpreferably less than 8%; the material enters a pellet mill forcompaction if desired and then is reduced in size in a crumbler ifdesired. If needed, the material exiting the drum is passed through ahigh pressure drop, low air flow fluid bed to cool the material furtherbefore sending it to a pellet mill for compaction. The heated air fromthis fluid bed is recycled back into Zone 1 of the rotaryReactor-Evaporator Drum.

In another embodiment, a Reactor-Evaporator Drum with five zones isused. However, any desired number of zones can be utilized, such as 7zones may also be used, separated by baffles. Each zone is designed tooptimize the process for that zone. The first zone of the five zone drumis the acidifying zone. In this zone, the acid and/or source of acid canbe added to the litter so that the material remains free flowing. Thesecond zone is where the ammonia and water and/or source of ammonia isadded so that the ammoniating takes place and is downstream from theacidifying zone. In the ammoniating zone, preferably anhydrous ammoniais added or ammonium hydroxide (a source of ammonia) which reacts withthe acidified material produced in the first zone. Water is also addedin the ammoniating zone to dissolve the ammonium salt created by thechemical reaction of the acid with the ammonia on the surface of theparticles. In both the first and second zone, heat is generated so thatthe temperature of the material is increased preferably to greater than65.6° C. (150° F.), more preferably greater than 82.2° C. (180° F.),more preferably greater than 90° C. (194° F.), and most preferablygreater than 98.9° C. (210° F.).

The material enters the next zone of the Reactor-Evaporator Drum whichis another acidifying zone as described previously. Then the materialpasses to another ammoniating zone where both ammonia or an ammoniasource and water are added as described previously, and finally to theevaporative drying and cooling zone which is as described previously.The poultry liter-based fertilizer leaving the drum preferably has amoisture content of less than 12%, more preferably less than 10%, andmost preferably less than 8% water.

Alternatively, the Reactor-Evaporator Drum may be modified to have sevenzones with the first four as the first four described above and the lastthree being an additional acidifier zone followed by an ammoniating zonefollowed by an evaporative cooling zone. As another alternative ifdesired, the Reactor-Evaporator Drum may be designed with either fourzones or six zones eliminating the last evaporative cooling zone fromthe five zone or seven zone Reactor-Evaporator Drums respectively. Inthe case of the four zone and six zone drums, the final evaporativecooling step when needed is performed in a separate drum, a fluid bed,or other drying and cooling technology known to those familiar in theart of drying and cooling material.

For the present invention, granular fertilizer means fertilizerparticles that are formed by agglomeration of smaller particles heldtogether by the crystallization of compounds formed during the reactionof materials in the process.

Pelletized refers to particles formed through compaction of smallerparticles.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1A: a process flow diagram of the process for converting poultrylitter to valuable fertilizer using a single Reactor-Evaporator Drumwith multiple zones

FIG. 1B: a continuation of FIG. 1A

FIG. 2: an example pH profile for material passing through thesequential zones of a Reactor-Evaporator Drum

FIG. 3: an example temperature curve for material passing through thesequential zones of a Reactor-Evaporator Drum

FIG. 4: an example moisture curve for material passing through thesequential zones of a Reactor-Evaporator Drum

FIG. 5: a process flow diagram of the process for converting poultrylitter to valuable fertilizer using two Reactor-Evaporator Drums withmultiple zones.

FIG. 6: a continuation of the process flow diagram of FIG. 5.

FIG. 7: a schematic longitudinal cross-sectional elevation view of aReactor-Evaporator Rotary Drum embodying the principles of the presentinvention, with some parts omitted for clarity;

FIG. 8: a cross-sectional plan view of the Reactor-Evaporator RotaryDrum of FIG. 7 illustrating locations of acid injection inlets, scrubbersolution discharge inlets, ammonia injection spargers, and wash waterinlets with some parts omitted for clarity;

FIG. 9: a schematic cross-sectional end view of the inlet end of thedrum of FIG. 7 looking in the direction of the arrows Z0-Z0;

FIG. 10: a schematic cross-sectional view of Zone 1 and Zone 4(acidifying zones) of the drum of FIG. 7 looking in the direction of thearrows Z1-Z1 and Z4-Z4 respectively;

FIG. 11: a schematic cross-sectional view of Zone 2 and Zone 5(ammoniating zones) of the drum of FIG. 7 looking in the direction ofthe arrows Z2-Z2 and Z5-Z5 respectively;

FIG. 12: a schematic cross-sectional view of Zone 3 and Zone 6(evaporative cooling zones) of the drum of FIG. 7 looking in thedirection of the arrows Z3-Z3 and Z6-Z6 respectively;

DETAILED DESCRIPTION OF THE INVENTION

The invention will be explained by reference to attached non-limitingfigures.

Referring to FIGS. 1A and 1B.

Pre-processed Raw Poultry Litter (10) that is typically at 20-30%moisture; has removed from it solid contaminants like metal, glass, andplastic; and has been milled to pass through a 0.48 cm to 1.27 cm ( 3/16inch to ½ inch) screen is precisely metered into a modified rotaryReactor-Evaporator Drum (30) (also referred to as a vessel) havingmultiple Zones (also referred to as chambers) separated by baffles.

If desired, metals and/or metal oxides and/or metal salts can beprecisely metered (12) into Zone 1 to increase the secondary nutrientsand/or micronutrients in the final product.

During Step 1 of the drum process, the litter (10) enters Zone 1 of theReactor-Evaporator Drum (30) where acid (51) and/or source of acid (suchas oleum and/or sulfur trioxide) is added (14) to lower the pH, generateheat, react with the nitrogen compounds and other odor producingcompounds in the litter to stabilize them, and to react with metals ormetal oxides to produce plant-available nutrients. Scrubber DischargeSolution (54) may also be added in Zone 1. The acid and/or source ofacid can be added in amount so that the acidified material has a pH ofless than 3, preferably less than 2, more preferably less than 1. Theheat generated and the low pH of 3 or less kills pathogens, destroysdrugs, kills weed seeds, and drives off moisture present in the litter.The acid and/or source of acid can be sprayed onto the falling materialin Zone 1.

Next in Step 2, the now acidified material enters Zone 2 of theReactor-Evaporator Drum (30) where ammonia (18) and/or source of ammoniais added (19) into the acidified material. Preferably ammonia (18) orammonium hydroxide (source of ammonia) is added to react with theacidified material in the drum bed and thereby produce an ammonium saltor ammonium salts as well as generate additional heat. The ammoniaand/or source of ammonia can be sprayed into the acidified materialfalling in the Zone 2. The ammonia and/or source of ammonia can be addedin an amount to raise the pH of the ammoniated mixture not to exceedpreferably 6.4, more preferably 6.2 and most preferably 6.0. The pH ispreferably not raised too high to retain the ammonium in solid or liquidform and avoid forming ammonia gas. Although counterintuitive toproducing a dry product; water (26), wash water (20), and/or scrubbersolution (54) is sprayed onto the material during this step. This is anecessary and surprising solution to the unexpected problem of ammoniumsulfate forming a crust on the surface of the forming granules so thatammonia cannot penetrate into the granule and react with acid. Addingwater is necessary to allow the addition of more sulfuric acid and thereaction of more ammonia to elevate the levels of nitrogen and at thesame time raise the pH of the product above 4.0. Without the addition ofwater, the ammonia never penetrates the granule and the acid on theinside of the granule does not react resulting in a product with a pHbelow 4.0 or a product with a nitrogen level below 6%. Any producedammonia in the air stream through the drum can be scrubbed with acid toretain it in the system and prevent producing a waste stream.

For Step 3, the ammoniated material now enters Zone 3, the firstevaporative cooling zone of Reactor-Evaporator Drum (30). In Zone 3,water is evaporated and swept away by air entering the drum (16) andflowing through the Zones. If needed to promote further evaporativecooling, water (26) can be sprayed (21) in any of the Zones. The wateradded can be wash water (20) when available from wash down of theequipment and surrounding areas, or a waste stream. Scrubber Solution(54) may also be sprayed in Zone 3.

Before subjecting the ammoniated material to another acidification step,the ammoniated material must be dried and cooled to maintain asemi-solid or solid particulate form that is free-flowing. If the watercontent is too high, ammonium salts will dissolve and form clumpedmaterial that is not free-flowing. After the ammoniated material hasdried and cooled to below 80° C. (176° F.), more preferably to below76.7° C. (170° F.), more preferably below 71.1° C. (160° F.), and mostpreferably below 65.6° C. (150° F.); the dried and cooled ammoniatedmaterial enters Zone 4 of Reactor-Evaporator Drum (30) where it is againacidified as described in Step 1 above. Next, the acidified materialenters Zone 5 of Reactor-Evaporator Drum (30) where it is againammoniated as described in Step 2 above to form an ammoniated material.In Zone 5, the final ammoniating step, only water (26) is sprayed todissolve ammonium salt crust on the granule and to cool the material.Wash water (20) is not sprayed since it may contain unreacted chickenlitter and Scrubber Solution (54) is not sprayed since it may containsulfuric acid that may not have the opportunity to react.

In the final step, the ammoniated material having a desired nitrogencontent enters Zone 6 of the Reactor-Evaporator Drum (30), anotherevaporative cooling zone where the litter is cooled until thetemperature is less than 80° C. (176° F.), more preferably less than71.1° C. (160° F.), more preferably less than 65.6° C. (150° F.), andmost preferably less than 54.4° C. (130° F.). In Zone 6, water isevaporated and swept away by air entering the drum (16). If needed topromote further evaporative cooling, water (26) can be sprayed (27).

The acidification, ammoniating, and drying and cooling steps can berepeated as desired to increase the nitrogen content in the finalproduct to a desired level.

The off-gases and dust (56) from the Reactor-Evaporator Drum (30) andother dust collection equipment are passed through the Screen (85) toseparate solids from the gas stream. These Off-Gas Solids (86) can berecycled back to feed into the drum (30) with the Pre-Processed PoultryLitter (10)

The essentially solids-free off-gases from Screen (85) pass to theScrubber (50) where they are scrubbed with acid (52). The scrubberdischarge solution (waste stream) can be recycled (54) back intoReactor-Evaporator Drum (30) in Zone 1 and/or Zone 4.

The treated litter exits Reactor-Evaporator Drum (30) and if furthercooling is needed is sent to Fluid Bed (60). The heated air from FluidBed (60) is recycled back (17) into the air (16) sent toReactor-Evaporator Drum (30).

The entire process through the drum (30) can be conducted in acontinuous manner, with new poultry litter continuously being added tothe input of the drum (30) and dried poultry litter-based fertilizerbeing continuously expelled from the drum (30). The continuous processcan surprisingly be conducted with no additional heat from burningfossil fuels, no significant carbon dioxide expelled, and no significantcontaminants expelled. The main components expelled from the drum (30)are only water vapor to remove heat and the final poultry litter-basedfertilizer product. An air stream can be continuously flowed through theZones in the drum (30) to help remove the heat and water vapor from thedrum (30), and any contaminates, acid or ammonia in the air stream canbe removed using a screen and a scrubber. A waste stream from thescrubber can be supplied any of the Zones before the final ammoniatingzone and evaporative cooling zone.

The fertilizer is now sufficiently granulated leaving the drum but if aharder and less friable product is desired, the fertilizer now may besent to Pellet Mill (40) where the material is pelletized.

If pelletized, next, the fertilizer enters a Crumbler (42) where thesize of the pellets is reduced.

The final dry pelletized fertilizer is sent to a Sieve (44) and thescreened product is separated from the undersize material (46) which canbe recycled back to Pellet Mill (40).

By repeatedly processing the poultry litter through a series of chemicalreactions using acids and/or oleum and/or sulfur trioxide followed bybases and water and providing a zone for evaporation; the nitrogenlevels and/or sulfur levels are elevated; the secondary nutrient levelsand/or micronutrient levels are elevated if desired; the phosphorus andpotassium levels are reduced; the organic carbon level is preferablygreater than 10%, more preferably greater than 18%, and most preferablygreater than 20%; and the product is dried. Based on the presentdescription, one skilled in the art will be enabled to modify the priorart Reactor-Evaporator Drum as desired to provide any desired additionalacidifying, ammoniating, and evaporative drying and cooling zones asneeded.

A plant producing 2.72 metric tons per hour (3.00 U.S., tons/hour) ofproduct running for 24 hours using poultry litter with 30% moisturecontent and producing a product with 10% nitrogen would require 19.0 kg(41.8 pounds) of water for every 45.4 kg (100 pounds) of productproduced. This is equal to 27,342 liters (7,223 gallons) of water perday. Water used may be in the form of clean water, reclaimed water,plant wash down water (wash water), and/or scrubber discharge solution.The use of plant wash down water and scrubber discharge solution aswater in the process provides benefits beyond emissions control, it alsomeans that there is less utility water demand which is especiallyimportant for areas with low levels of available potable water.

Referring to FIG. 2.

One possible pH profile of the material as it passes through the processin Reactor-Evaporator Drum (30) is shown. With addition of sulfuric acidin Zone 1, the pH of the material drops dramatically. Next, as ammoniais added in Zone 2, the pH of the material is increased but not allowedto exceed preferably 6.4, more preferably 6.2 and most preferably 6.0.The pH of the material does not change in the evaporative cooling zone,Zone 3. These steps repeat again respectively in Zone 4, Zone 5, andZone 6; and the final pH of the particulate material does not exceedpreferably 6.4, more preferably 6.2 and most preferably 6.0.

Referring to FIG. 3.

One possible temperature profile of the litter as it passes through theprocess in the Reactor-Evaporator drum is shown. With the addition ofsulfuric acid, the litter begins to heat due to heat of dilution andheat of reaction and with ammonia in the poultry litter. Next, as theammonia is added, the litter heats further due to the heat of reaction.The litter is cooled dramatically in the evaporative cooling zone. Thesesteps repeat again with the litter exiting at a temperature less than apredetermined target temperature.

Referring to FIG. 4.

Possible moisture profiles for the litter are provided as it passesthrough the process using either sulfuric acid or oleum in theAcidifying Zones 1 and 4. As can be seen, the moisture may rise slightlywith the addition of some water in the sulfuric acid. However, with theuse of oleum, water is used up by the reaction of sulfur trioxide withwater in the litter to produce sulfuric acid. Although water is sprayedduring the ammoniating step, the moisture decreases slightly in theAmmoniating Zones 2 and 5 due to evaporative cooling. The moisturedecreases dramatically in the Evaporative Cooling Zones 3 and 6. Thelitter exiting the Reactor-Evaporator Drum is essentially free ofmoisture based on the desired moisture levels of the product.

Referring to FIG. 5 and FIG. 6.

Pre-processed Raw Poultry Litter (10) that is typically at 20-30%moisture; has removed from it solid contaminants like metal, glass, andplastic; and has been milled to pass through a 0.48 cm to 1.27 cm ( 3/16inch to ½ inch) screen is precisely metered into a rotaryReactor-Evaporator Drum 1 (31).

If desired, metals and/or metal oxides and/or metal salts are preciselymetered (12) into Zone 1 to increase the secondary nutrients and/ormicronutrients in the final product.

The litter (10) enters Zone 1 of Reactor-Evaporator Drum 1 (31) whereacid (51) (and/or oleum and/or sulfur trioxide) is added (14) to lowerthe pH, generate heat, react with the nitrogen compounds and other odorproducing compounds in the litter to stabilize them, and to react withmetals or metal oxides to produce plant-available nutrients. The heatgenerated and the low pH kills pathogens, destroys drugs, kills weedseeds, and drives off moisture present in the litter. Scrubber DischargeSolution (54) may also be added in Zone 1 of Drum (31).

Next, the now acidified litter enters Zone 2 of Reactor-Evaporator Drum1 (31) where a base is added (24) to the litter, preferably ammonia (18)or ammonium hydroxide, to react with the acidified litter in the drumbed and thereby produce an ammonium salt or ammonium salts as well asgenerate additional heat. Water (26) and/or Wash Water (20) is alsosprayed to dissolve ammonium salt that forms on the surface of granulesas they form and thereby ensure that the base reacts with acid at thecenter of the granule. Scrubber Solution (54) may also be sprayed inthis Zone to dissolve ammonium salt and to cool the material.

The treated litter now enters Zone 3, the evaporative cooling zone ofReactor-Evaporator Drum 1 (31). In Zone 3, water is evaporated and sweptaway by air entering the drum (17). If needed to promote furtherevaporative cooling, Water (26) is sprayed (22). The water added may bewash water (20) when available from wash down of the equipment andsurrounding areas and/or Scrubber Solution (54) may be used.

After the treated litter has cooled preferably to below 80° C. (176°F.), more preferably to below 76.7° C. (170° F.), more preferably below71.1° C. (160° F.), and most preferably below 65.6° C. (150° F.); itexits Reactor-Evaporator Drum 1 (31) and enters Zone 1 of theReactor-Evaporator Drum 2 (32) where acid (51) (and/or oleum and/orsulfur trioxide) is added (15) to lower the pH, generate heat, reactwith the nitrogen compounds and other odor producing compounds in thelitter to stabilize them, and to react with metals or metal oxides toproduce plant-available nutrients. The heat generated and the low pHkills pathogens, destroys drugs, kills weed seeds, and drives offmoisture present in the litter. Scrubber Discharge Solution (54) mayalso be added in Zone 1 of Drum (32).

Next, the treated litter enters Zone 2 of Reactor-Evaporator Drum 2(32); water (26) is sprayed and a base is added (19) to the litter,preferably ammonia (18) or ammonium hydroxide, to react with theacidified litter in the drum bed and thereby produce an ammonium salt orammonium salts as well as generate additional heat. Water (26) issprayed to dissolve ammonium salt that forms on the surface of granulesas they form and thereby ensure that the base reacts with acid at thecenter of the granule.

Next, the treated litter enters Zone 3 of Reactor-Evaporator Drum 2(32), another evaporative cooling zone where the litter is cooled untilthe temperature is preferably less than 71.1° C. (160° F.), morepreferably less than 65.5° C. (150° F.), and most preferably less than54.4° C. (130° F.). In Zone 3 of Reactor-Evaporator Drum 2 (32), wateris evaporated and swept away by air entering the drum (17). If needed topromote further evaporative cooling, Water (26) is sprayed (21).

The off-gases and dust (56) from Reactor-Evaporator Drum 1 (31) and fromReactor-Evaporator Drum 2 (32) and from other dust collecting equipmentpass through Screen (85) to separate the solids from the gases. TheOff-Gas Solids (86) are recycled back into the Reactor-Evaporator Drum 1(31) by adding them to the Pre-Processed Poultry Litter (10) beingmetered into the drum in Zone 1. The gases from Screen (85) pass throughScrubber (50) where they are scrubbed with acid (52). The ScrubberDischarge Solution (54) is recycled back into Reactor-Evaporator Drum 1(31) and/or Reactor-Evaporator Drum 2 (32) in Zones 1 and/or 2 and/or 3of Reactor-Evaporator Drum 1 (31) and Zone 1 of Reactor-Evaporator Drum2 (32).

The dry treated litter exits Reactor-Evaporator Drum 2 (32) and iffurther cooling is needed is sent to Fluid Bed (60). The heated air fromFluid Bed (60) is recycled back into the air (17) sent toReactor-Evaporator Drum 1 (31) and Reactor-Evaporator Drum 2 (32).

The fertilizer is now sufficiently granulated leaving the drum but if aharder and less friable product is desired, the fertilizer enters PelletMill (40) where the material is pelletized.

If pelletized, next, the fertilizer is sent to Crumbler (42) where thesize of the pellets is reduced.

The dry fertilizer is sent to Sieve (44) and the screened product isseparated from the undersize material which is recycled (46) back toPellet Mill (40).

By repeatedly processing the poultry litter through a series of chemicalreactions using acids and/or oleum and/or sulfur trioxide followed bybases, adding water to dissolve ammonium crust on granules, andproviding a zone for evaporation; the nitrogen levels and/or sulfurlevels are elevated; the secondary nutrient levels and/or micronutrientlevels can now be elevated if desired; and the phosphorus and potassiumlevels are reduced. Additional Reactor-Evaporator Drums may be utilizedas needed.

Referring to FIGS. 7, 8, 9, 10, 11, and 12;

The Reactor-Evaporator Drum (30) shown in FIG. 7 includes a cylindricalside wall (100), an inlet end plate (120) having an axial inlet opening(140), and an outlet end plate (160) having an axial discharge opening(180). The Reactor-Evaporator Drum (30) is supported and rotatablydriven in any conventional fashion and is slightly inclined downwardlytoward its discharge end so that particulate material introduced throughthe inlet opening (140) by a chute (190) will travel through the drum(30) and be discharged through the discharge opening (180). Asillustrated schematically in FIG. 9, the drum (30) can be supported onrollers (200) and rotatably driven by a motor (M) through a pinion (220)which engages a ring gear (240) secured to the drum side wall (100).

Particulate material entering the drum (30) enters Zone 1 of FIG. 7,which is also shown as a cross-sectional view in FIG. 10, in which it isacidified. This acidifying zone is fitted with lifting flights (280)secured to the drum side wall (100). The flights (280) are canted in adirection opposite the direction of rotation of the drum (30), relativeto an axial plane passing through the axis of the drum. A particularlysuitable cant angle is 45°. Upon rotation of the Drum (30), flights(280) lift the particulate material in Zone 1 and drop it so that itfalls and cascades as a stream or Curtain of Particulate Material (300).The bulk of the material rolls as a mass or bed of particulate matter(320) on the inner surface of the sidewall (100). The manner in whichthe flights (280) are canted ensures good mixing of the material withoutbuildup or reverse flow problems. The width of the flights (280) shouldbe between 10 and 20% of the drum's diameter.

The length of the flights (280) are the same as the length of Zone 1 inthat the downstream ends of the flights (280) form the downstream end ofZone 1. At the end of the flights (280), there is a ring (340) securedto the drum side wall (100). Particulate material passing over this ring(340) enters the first section (360) of Zone 2. This first section (360)of Zone 2 is free of flights and/or antiskid bars. The section (360)free of flights may be longer or shorter than shown or it may beomitted.

Downstream of the section (360) in Zone 2, ammonia is applied and whichin the illustrated embodiment is fitted with antiskid bars (400)extending essentially the length of Zone 2. The bars (400) may beapproximately 0.635 cm to 1.27 cm (¼ to ½ inch) in height to prevent thebed of particulate material (420) from slipping in Zone 2. As seen inFIG. 11, the bed (420) is a rolling bed of material in contact with theside wall (100), since the bars (400) are too low to function as liftingflights. Wash water (20) when available and/or water (26) is added inZone 2 by spraying onto the rolling Bed of Particulate Material (420)through Water and Wash Water Injection Nozzles (490). Scrubber DischargeSolution (54) may also be sprayed in Zone 2 through Scrubber DischargeSolution Injection Nozzles (461).

At the end of Zone 2, there is a ring (380) secured to the drum sidewall (100). Particulate material passing over this ring (380) entersZone 3, the evaporative cooling zone. This evaporative cooling zone isfitted with lifting flights (70) secured to the drum side wall (100).The flights (70) are canted in the same direction as the direction ofrotation of the drum (30), relative to an axial plane passing throughthe axis of the drum. Upon rotation of the Drum (30), flights (70) liftthe particulate material in Zone 3 and drop it so that FallingParticulate Material (78) is cascading off and is airborne throughoutthe center cross-section of Zone 3. The manner in which the flights (70)are canted ensures that the material in the Bed of Particulate Material(520) is lifted and carried so that it cascades throughout the wholecross-section of Zone 3 and so that much of the material is in contactwith the stream of air passing through the drum which maximizes theevaporation of water and the transfer of heat from the particulatematerial. The width of the flights (70) should be between 10 and 20% ofthe drum's diameter.

At the end of Zone 3, there is a ring (390) secured to the drum sidewall (100). Particulate material passing over this ring (390) entersZone 4. Zone 4 is another acidifying zone which duplicates the setup oflifting flights (280) of Zone 1.

At the end of Zone 4 is a ring (341) secured to the drum side wall(100). Particulate material passing over this ring enters Zone 5. Zone 5is another ammoniating zone which duplicates the setup of antiskid barsof Zone 2.

At the end of Zone 5 is a ring (381) secured to the drum side wall(100). Particulate material passing over this ring enters Zone 6. Zone 6is another evaporative cooling zone which duplicates the setup oflifting flights of Zone 3.

At the end of Zone 6 is a ring (391) secured to the end. Particulatematerial passing over this ring exits the Reactor-Evaporator Drum (30).

FIGS. 8, 9, 10, 11, and 12 show extending axially through the drum (30)a stationary support pipe (440) supported outside the drum by anysuitable means (not shown). The support pipe (440) is covered by anangled cap (75) to prevent buildup of material on the pipe. The pipe(440) is provided as a support structure for a plurality of acidinjection nozzles (460) in the acidifying zones of the drum (Zones 1 and4), as a support structure for ammonia sparge pipe (480) in theammoniating zones (Zones 2 and 5) of the drum (30), for a supportstructure for the Scrubber Discharge Solution Injection Nozzles (461) inthe first section of Zones 1, 2, 3, and 4, as a support structure forthe Water and Wash Water Injection Nozzles (490) in Zones 2 and 3, andas a support structure for the Water Injection Nozzles (491) in Zones 5and 6. The manner in which the nozzles (460, 461, 490, and 491) and thesparge pipe (480) are mounted on the support pipe (440) forms no part ofthe invention and need not be described. The mounting means of thenozzles (460, 461, 490, and 491) is shown generally respectively. Thenumber of nozzles may be more or less than the number shown.

The acid spray nozzles (460) are disposed in spaced relationship alongessentially the whole of the length of Zone 1 and Zone 4. The nozzlesare so located that their discharge orifices are aimed at the curtain(300) of free-falling material so that the Acid Spray (540) contacts thecurtain (300) near its lower end. Alternatively, if sulfur trioxide gasis used to acidify the litter in Zones 1 and 4, the gas is injectedbeneath the surface of the bed and antiskid bars are used instead oflifting flights in the manner explained in Zones 2 and 5. The ScrubberDischarge Solution Injection Nozzles (461) are in the initial length ofZone 1, Zone 2, Zone 3, and Zone 4. The nozzles are so located thattheir discharge orifices are aimed at the curtain (300) of free-fallingmaterial so that the Scrubber Discharge Solution Spray (541) contactsthe Curtain of Particulate Material (300) or at the fastest moving partof the Bed of Particulate Material (320) when lifting flights are notpresent. The location of the ammonia sparge pipe (480) is within the bedof particulate material (420) in Zones 2 and 5 near the lower end of thebed so that ammonia injected from orifices (560) in the pipe (480) hasthe maximum time to disperse and react with the acidified particulatematerial before being exposed to the surface of the bed. The distance ofthe orifices (560) from the side wall of the drum (100) should be nogreater than ½ the depth of the bed of particulate material (420). Thediameter of the discharge opening (180) is such that, typically, a bedof about 25.4 cm (10 inches) exists in Zone 2 and Zone 5.

Water and Wash Water Injection Nozzles (490) are in Zone 2 and Zone 3.The nozzles are so located that their discharge orifices are aimed atthe fastest moving part of the Bed of Particulate Material (320). TheWater Injection Nozzles (491) are the length of Zone 5 and Zone 6. Thenozzles are so located that their discharge orifices are aimed at thefastest moving part of the Bed of Particulate Material (320).

Furthermore, any desired additives can be added to the system to provideany desired result, such as materials commonly added to fertilizers.

One preferred inventive fertilizer produced by the process has % N ofmore than 6%, more preferably more than 8%, and most preferably morethan 10%; moisture content of preferably less than 12% water, morepreferably less than 10% water, and most preferably less than 5% water;phosphorus content of less than 2%; sulfur content of more than 10%; andtotal other nutrient, secondary nutrient, and micronutrient content ofpreferably more than 2.5%, more preferably more than 3%, and mostpreferably more than 4%. All phosphorus, potassium and micronutrients inthe product originate from the starting litter supplied to the process.The product is comprised of up to 2.5% nitrogen resulting directly fromthe nitrogen in the starting poultry litter. Remaining nitrogen in theproduct results from ammonia used in the process.

The inventive fertilizer is free of noxious odors, pathogens, drugs,steroids, hormones, even when wet or stored in a humid environment. ThepH of the fertilizer product is preferably between 4 and 6.5 and morepreferably between 5 and 6.

In a preferred embodiment, the inventive fertilizer product containspreferably more than 11% organic carbon and more preferably more than14% carbon which results from the starting poultry litter.

A preferred form of the inventive fertilizer is a smooth, hard granulethat is 1 mm to 3 mm in size.

In a preferred embodiment, the fertilizer comprises at least 8% nitrogenand at least 13% of the nitrogen in the fertilizer is from nitrogen inthe starting poultry litter; 10% bedding material from poultry litter;0.91% potassium from potassium in the starting litter; at least 9%sulfur; and total other nutrient, secondary nutrient, and micronutrientcontent of preferably more than 2.5%, more preferably more than 3%, andmost preferably more than 4%.

In a preferred embodiment, the fertilizer comprises at least 30%ammonium sulfate, more preferably at least 40% ammonium sulfate, andmost preferably at least 45% ammonium sulfate.

In a preferred embodiment of the invention, water added during theprocess is added at weight of water per 45.4 kg (100 pounds) product foreach unit of nitrogen in the product at the rate in the range of 0.454kg to 2.72 kg (1 pound to 6 pounds) water, more preferably 0.907 kg to2.27 kg (2 pounds to 5 pounds) water, and most preferably 1.36 kg to2.04 kg (3 pounds to 4.5 pounds) water. A unit of nitrogen is 1 wt. %nitrogen by dry weight. Because of the large amount of water needed,plant wash down (wash water) and scrubber discharge solution can be usedto provide at least a portion of this water. The product resulting fromthe process is less than 10% moisture. Furthermore, no fossil fuels areneeded in the process and there are no waste streams generated by theprocess except water vapor.

It is to be understood that the foregoing illustrative embodiments havebeen provided merely for the purpose of explanation and are in no way tobe construed as limiting of the invention. Words used herein are wordsof description and illustration, rather than words of limitation. Inaddition, the advantages and objectives described herein may not berealized by each and every embodiment practicing the present invention.Further, although the invention has been described herein with referenceto particular structure, steps and/or embodiments, the invention is notintended to be limited to the particulars disclosed herein. Rather, theinvention extends to all functionally equivalent structures, processesand uses, such as are within the scope of the appended claims. Thoseskilled in the art, having the benefit of the teachings of thisspecification, may affect numerous modifications thereto and changes maybe made without departing from the scope and spirit of the invention.

EXAMPLES

Statements that can be made from the Examples below.

It was observed in the examples that when the material began toaccumulate a white crust on the granules during the ammoniating stepthat the pH of the material would stay low (below 5.5) no matter howmuch ammonia was sparged. At this point water was sprayed onto the bedof material to dissolve the white crust forming and the pH would againbegin to rise as the ammonia reacted with the sulfuric acid. Severalexamples were done to adjust the application of acid, water, and ammoniato check the resulting product for nitrogen level, moisture, sizedistribution, crush strength, and to have enough to pelletize.

The fertilizer product produced was granular with a crush strength of atleast 4.45 newtons (1.55 pounds) and a moisture of between 8% and 12%.About 90% of the granular product was in the in 1 mm to 3.35 mm sizerange.

The nitrogen in the starting litter was 2.75% and all of this nitrogenfrom the starting litter was contained in the final product.

1. The carbon in the products came from the starting litter and wasgreater than 10%.

2. The K₂O in the starting litter was greater than 2.9% K₂O (2.4% K).

3. The K₂O in the products was from the starting litter and was greaterthan 1.1% K₂O (0.91% K).

Example 1

For this example, a smooth, round, hard granular fertilizer product wasproduced with a nitrogen level of 10.4%. To accomplish this and as wellas Examples 2-12, the litter was passed through three sets of acidifyingand ammoniating steps and water was added during the ammoniating stepeach time.

Poultry litter from the clean out of a poultry house in Carthage, Miss.was used as the poultry litter source for the process. This poultryhouse used pine shavings as their bedding material. The houses werede-caked every seven weeks and the clean out was done after two years ofde-caking. The litter was milled to pass a 0.48 cm ( 3/16 inch) screen.The moisture in the milled litter was 22%. The litter was analyzed fornutrient content and the results are shown in Table 1.

TABLE 1 Mississippi Raw Litter Analysis % N % P₂O₅ % K₂O % S % Zn % Mg %Ca % Fe % Al % Mn % Mo % B % Cu 2.75 3.51 2.93 1.36 0.04 0.58 2.73 0.220.37 0.04 0.00 0.004 0.014

Step 1: First Acidifying Step

0.68 kg (1.5 pounds) of litter was placed in a 50.8 cm (20 inch)diameter rotary Acidifying Drum (AcD) equipped with lifting flights.With AcD running at a speed to produce a falling curtain of material,0.138 kg (0.305 pounds) of 98% sulfuric acid was sprayed onto the baseof the falling curtain using a SS Unitjet 11001 spray nozzle. Theacidified material was transferred to a second 50.8 cm (20 inch)diameter rotary Ammoniating Drum (AmD) equipped with anti-slip rods.Another 0.68 kg (1.5 pounds) of litter was placed in the AcD and sprayedas before with 0.139 kg (0.306 pounds) of 98% sulfuric acid. This secondbatch of acidified litter was transferred to the AmD.

Step 2: First Ammoniating Step:

With both batches of acidified litter from Step 1 in AmD, AmD was run ata speed to produce a rolling bed of material and ammonia was spargedinto the deepest part of the bed. The pH of the material was measuredusing pH paper by crushing a few granules and wetting with water. Atotal of 0.0485 kg (0.107 pounds) of water was sprayed onto the bed ofmaterial. When the pH of the material reached 5.5, the ammonia wasstopped. The moisture was then measured at 13.9%.

Step 3: Second Acidifying Step

Half of the material from Step 2 was placed in AcD and as described inStep 1, was acidified with 0.107 kg (0.235 pounds) of 98% sulfuric acid.This was removed from AcD and the other half of material from Step 2 wasplaced in AcD and acidified with 0.122 kg (0.270 pounds) of 98% sulfuricacid.

Step 4: Second Ammoniating Step

Both of the acidified batches from Step 3 were combined in AmD andsparged as described before with ammonia until the pH was 6.0. Duringthe ammonia sparging, 0.184 kg (0.406 pounds) of water was added. Themoisture at the end of the ammoniating step was 9.3%

Step 5: Third Acidifying Step

Half of the material from Step 4 was placed in AcD and as described inStep 1, was acidified with 0.137 kg (0.301 pounds) of 98% sulfuric acid.This was removed from AcD and the other half of material from Step 4 wasplaced in AcD and acidified with 0.104 kg (0.0.229 pounds) of 98%sulfuric acid.

Step 6: Third Ammoniating Step

Both of the acidified batches from Step 5 were combined in AmD andsparged as described before with ammonia until the pH was 5.5. Duringthe ammonia sparging, 0.196 kg (0.432 pounds) of water was added. Themoisture of the final product was 8.7%. The weight of the fertilizerproduced was 2.23 kg (4.91 pounds).

Example 2

This example tested the enhancement of the product with zinc by addingzinc oxide to the starting litter. The nutrient analysis of the productis given in Table 3. The resulting product was a smooth, round, hardgranule with almost all of the product in the size range of 1 mm to 3.35mm and a nitrogen level of 10.2%.

Using the same milled and screened litter as Example 1, 14.7 g of zincoxide was split into two batches and added to the material in therotating AcD before the acid was sprayed. After adding the zinc oxide,the same steps were followed as described for Example 1 noting thefollowing parameters for each step.

Step 1: First Acidifying Step

0.137 kg (0.301 pounds) of 98% sulfuric acid was sprayed on the first0.68 kg (1.5 pounds) of litter and 0.140 kg (0.308 pounds) of 98%sulfuric acid was sprayed on the second 0.68 kg (1.5 pounds) of litter.

Step 2: First Ammoniating Step

Ammonia was sparged into the combined batches from Step 1 until the pHwas 7.0. The water added during the ammoniating step was 0.111 kg (0.245pounds) and the final moisture was 14.2%

Step 3: Second Acidifying Step

0.140 kg (0.308 pounds) of 98% sulfuric acid was sprayed on half of thematerial from Step 2 and 0.140 kg (0.308 pounds) of 98% sulfuric acidwas sprayed on the second half of the material from Step 2.

Step 4: Second Ammoniating Step

Ammonia was sparged into the combined batches from Step 3 until the pHwas 5.5. The water added during this ammoniating step was 0.208 kg(0.458 pounds) and the final moisture was 12.6%

Step 5: Third Acidifying Step

0.146 kg (0.321 pounds) of 98% sulfuric acid was sprayed on half of thematerial from Step 4 and 0.123 kg (0.272 pounds) of 98% sulfuric acidwas sprayed on the second half of the material from Step 4.

Step 6: Third Ammoniating Step

Ammonia was sparged into the combined batches from Step 5 until the pHwas 5.5. The water added during this ammoniating step was 0.194 kg(0.427 pounds) and the moisture of the final product was 13.0%

Examples 3 to 12 were made with very similar procedures with somevariation in the amount of water applied during the ammoniating step.

Example 3

Using the same milled and screened litter as Example 1, the litter wassplit into two equal sized batches and the same steps were followed asdescribed for Example 1 noting the following parameters for each step.

Step 1: First Acidifying Step

0.0921 kg (0.230 pounds) of 98% sulfuric acid was sprayed on the first0.68 kg (1.5 pounds) of litter and 0.0880 kg (0.194 pounds) of 98%sulfuric acid was sprayed on the second 0.68 kg (1.5 pounds) of litter.

Step 2: First Ammoniating Step

Ammonia was sparged into the combined batches from Step 1 until the pHwas 6.0. The water added during the ammoniating step was 0.0373 kg(0.082 pounds) and the final moisture was 15.0%

Step 3: Second Acidifying Step

0.117 kg (0.256 pounds) of 98% sulfuric acid was sprayed on half of thematerial from Step 2 and 0.0868 kg (0.191 pounds) of 98% sulfuric acidwas sprayed on the second half of the material from Step 2.

Step 4: Second Ammoniating Step

Ammonia was sparged into the combined batches from Step 3 until the pHwas 5.5. The water added during this ammoniating step was 0.445 kg(0.980 pounds) and the final moisture was 11.4%

Step 5: Third Acidifying Step

0.0864 kg (0.190 pounds) of 98% sulfuric acid was sprayed on half of thematerial from Step 4 and 0.0973 kg (0.214 pounds) of 98% sulfuric acidwas sprayed on the second half of the material from Step 4.

Step 6: Third Ammoniating Step

Ammonia was sparged into the combined batches from Step 5 until the pHwas 5.5. The water added during this ammoniating step was 0.147 kg(0.324 pounds) and the moisture of the final product was 9.2%. Theweight of product produced was 1.71 kg (3.76 pounds).

Example 4

Using the same milled and screened litter as Example 1, the litter wassplit into two equal sized batches and the same steps were followed asdescribed for Example 1 noting the following parameters for each step.

Step 1: First Acidifying Step

0.117 kg (0.256 pounds) of 98% sulfuric acid was sprayed on the first0.68 kg (1.5 pounds) of litter and 0.0936 kg (0.206 pounds) of 98%sulfuric acid was sprayed on the second 0.68 kg (1.5 pounds) of litter.

Step 2: First Ammoniating Step

Ammonia was sparged into the combined batches from Step 1 until the pHwas 5.75. The water added during the ammoniating step was 0.0464 kg(0.102 pounds) and the final moisture was 13.9%

Step 3: Second Acidifying Step

0.0968 kg (0.213 pounds) of 98% sulfuric acid was sprayed on half of thematerial from Step 2 and 0.120 kg (0.263 pounds) of 98% sulfuric acidwas sprayed on the second half of the material from Step 2.

Step 4: Second Ammoniating Step

Ammonia was sparged into the combined batches from Step 3 until the pHwas 6.0. The water added during this ammoniating step was 0.0977 kg(0.215 pounds) and the final moisture was 11.3%

Step 5: Third Acidifying Step

0.112 kg (0.245 pounds) of 98% sulfuric acid was sprayed on half of thematerial from Step 4 and 0.0909 kg (0.200 pounds) of 98% sulfuric acidwas sprayed on the second half of the material from Step 4.

Step 6: Third Ammoniating Step

Ammonia was sparged into the combined batches from Step 5 until the pHwas 5.5. The water added during this ammoniating step was 0.143 kg(0.314 pounds) and the moisture of the final product was 11.2%. Theweight of product produced was 1.91 kg (4.21 pounds)

Example 5

Using the same milled and screened litter as Example 1, the litter wassplit into two equal sized batches and the same steps were followed asdescribed for Example 1 noting the following parameters for each step.

Step 1: First Acidifying Step

0.110 kg (0.243 pounds) of 98% sulfuric acid was sprayed on the first0.68 kg (1.5 pounds) of litter and 0.0823 kg (0.181 pounds) of 98%sulfuric acid was sprayed on the second 0.68 kg (1.5 pounds) of litter.

Step 2: First Ammoniating Step

Ammonia was sparged into the combined batches from Step 1 until the pHwas 6.0. No water was added during this ammoniating step. The finalmoisture was 15.4%

Step 3: Second Acidifying Step

0.0873 kg (0.192 pounds) of 98% sulfuric acid was sprayed on half of thematerial from Step 2 and 0.0809 kg (0.178 pounds) of 98% sulfuric acidwas sprayed on the second half of the material from Step 2.

Step 4: Second Ammoniating Step

Ammonia was sparged into the combined batches from Step 3 until the pHwas 6.0. The water added during this ammoniating step was 0.0595 kg(0.131 pounds) and the final moisture was 12.4%

Step 5: Third Acidifying Step

0.0868 kg (0.191 pounds) of 98% sulfuric acid was sprayed on half of thematerial from Step 4 and 0.0941 kg (0.207 pounds) of 98% sulfuric acidwas sprayed on the second half of the material from Step 4.

Step 6: Third Ammoniating Step

Ammonia was sparged into the combined batches from Step 5 until the pHwas 5.75. The water added during this ammoniating step was 0.0632 kg(0.139 pounds) and the moisture of the final product was 10.2%. Theweight of product produced was 1.63 kg (3.59 pounds).

Example 6

Using the same milled and screened litter as Example 1, the litter wassplit into two equal sized batches and the same steps were followed asdescribed for Example 1 noting the following parameters for each step.

Step 1: First Acidifying Step

0.101 kg (0.223 pounds) of 98% sulfuric acid was sprayed on the first0.68 kg (1.5 pounds) of litter and 0.102 kg (0.0.224 pounds) of 98%sulfuric acid was sprayed on the second 0.68 kg (1.5 pounds) of litter.

Step 2: First Ammoniating Step

Ammonia was sparged into the combined batches from Step 1 until the pHwas 7.0. No water was added during this ammoniating step. The finalmoisture was 14.3%

Step 3: Second Acidifying Step

0.103 kg (0.227 pounds) of 98% sulfuric acid was sprayed on half of thematerial from Step 2 and 0.102 kg (0.224 pounds) of 98% sulfuric acidwas sprayed on the second half of the material from Step 2.

Step 4: Second Ammoniating Step

Ammonia was sparged into the combined batches from Step 3 until the pHwas 5.5. The water added during this ammoniating step was 0.0955 kg(0.210 pounds) and the final moisture was 9.5%

Step 5: Third Acidifying Step

0.103 kg (0.227 pounds) of 98% sulfuric acid was sprayed on half of thematerial from Step 4 and 0.0986 kg (0.217 pounds) of 98% sulfuric acidwas sprayed on the second half of the material from Step 4.

Step 6: Third Ammoniating Step

Ammonia was sparged into the combined batches from Step 5 until the pHwas 5.5. The water added during this ammoniating step was 0.184 kg(0.405 pounds) and the moisture of the final product was 10.0%. Theweight of the product was 1.88 kg (4.15 pounds).

Example 7

Using the same milled and screened litter as Example 1, the litter wassplit into two equal sized batches and the same steps were followed asdescribed for Example 1 noting the following parameters for each step.

Step 1: First Acidifying Step

0.103 kg (0.226 pounds) of 98% sulfuric acid was sprayed on the first0.68 kg (1.5 pounds) of litter and 0.100 kg (0.0.220 pounds) of 98%sulfuric acid was sprayed on the second 0.68 kg (1.5 pounds) of litter.

Step 2: First Ammoniating Step

Ammonia was sparged into the combined batches from Step 1 until the pHwas 5.8. No water was added during this ammoniating step. The finalmoisture was 14.7%

Step 3: Second Acidifying Step

0.104 kg (0.228 pounds) of 98% sulfuric acid was sprayed on half of thematerial from Step 2 and 0.100 kg (0.220 pounds) of 98% sulfuric acidwas sprayed on the second half of the material from Step 2.

Step 4: Second Ammoniating Step

Ammonia was sparged into the combined batches from Step 3 until the pHwas 5.5. The water added during this ammoniating step was 0.154 kg(0.339 pounds) and the final moisture was 11.9%

Step 5: Third Acidifying Step

0.103 kg (0.226 pounds) of 98% sulfuric acid was sprayed on half of thematerial from Step 4 and 0.105 kg (0.230 pounds) of 98% sulfuric acidwas sprayed on the second half of the material from Step 4.

Step 6: Third Ammoniating Step

Ammonia was sparged into the combined batches from Step 5 until the pHwas 5.0. The water added during this ammoniating step was 0.156 kg(0.343 pounds) and the moisture of the final product was 12.2%. Theweight of the product was 1.94 kg (4.27 pounds).

Example 8

Using the same milled and screened litter as Example 1, the litter wassplit into two equal sized batches and the same steps were followed asdescribed for Example 1 noting the following parameters for each step.

Step 1: First Acidifying Step

0.102 kg (0.224 pounds) of 98% sulfuric acid was sprayed on the first0.68 kg (1.5 pounds) of litter and 0.104 kg (0.0.229 pounds) of 98%sulfuric acid was sprayed on the second 0.68 kg (1.5 pounds) of litter.

Step 2: First Ammoniating Step

Ammonia was sparged into the combined batches from Step 1 until the pHwas 7.5. No water was added during this ammoniating step. The finalmoisture was 12.7%

Step 3: Second Acidifying Step

0.0968 kg (0.213 pounds) of 98% sulfuric acid was sprayed on half of thematerial from Step 2 and 0.102 kg (0.224 pounds) of 98% sulfuric acidwas sprayed on the second half of the material from Step 2.

Step 4: Second Ammoniating Step

Ammonia was sparged into the combined batches from Step 3 until the pHwas 6.0. The water added during this ammoniating step was 0.170 kg(0.375 pounds) and the final moisture was 11.3%

Step 5: Third Acidifying Step

0.105 kg (0.231 pounds) of 98% sulfuric acid was sprayed on half of thematerial from Step 4 and 0.101 kg (0.223 pounds) of 98% sulfuric acidwas sprayed on the second half of the material from Step 4.

Step 6: Third Ammoniating Step

Ammonia was sparged into the combined batches from Step 5 until the pHwas 5.5. The water added during this ammoniating step was 0.141 kg(0.310 pounds) and the moisture of the final product was 11.2%. Theweight of the product was 1.90 kg (4.18 pounds).

Example 9

Using the same milled and screened litter as Example 1, the litter wassplit into two equal sized batches and the same steps were followed asdescribed for Example 1 noting the following parameters for each step.

Step 1: First Acidifying Step

0.102 kg (0.224 pounds) of 98% sulfuric acid was sprayed on the first0.68 kg (1.5 pounds) of litter and 0.102 kg (0.0.225 pounds) of 98%sulfuric acid was sprayed on the second 0.68 kg (1.5 pounds) of litter.

Step 2: First Ammoniating Step

Ammonia was sparged into the combined batches from Step 1 until the pHwas 6.5. No water was added during this ammoniating step. The finalmoisture was 13.8%

Step 3: Second Acidifying Step

0.103 kg (0.220 pounds) of 98% sulfuric acid was sprayed on half of thematerial from Step 2 and 0.118 kg (0.257 pounds) of 98% sulfuric acidwas sprayed on the second half of the material from Step 2.

Step 4: Second Ammoniating Step

Ammonia was sparged into the combined batches from Step 3 until the pHwas 5.5. The water added during this ammoniating step was 0.155 kg(0.341 pounds) and the final moisture was 14.3%

Step 5: Third Acidifying Step

0.104 kg (0.229 pounds) of 98% sulfuric acid was sprayed on half of thematerial from Step 4 and 0.101 kg (0.222 pounds) of 98% sulfuric acidwas sprayed on the second half of the material from Step 4.

Step 6: Third Ammoniating Step

Ammonia was sparged into the combined batches from Step 5 until the pHwas 5.5. The water added during this ammoniating step was 0.0868 kg(0.191 pounds) and the moisture of the final product was 11.1%. Theweight of the product was 2.07 kg (4.56 pounds).

The product from the last ammoniating step was analyzed for size using aCAMSIZER®. This analysis showed that 88.9% of the product ranged in sizebetween 1 mm and 3.35 mm (see Table 2 below). And the Mean Value Symm3was 0.882 which shows that the product was round as compared to aperfectly spherical number of 1.0. It was also noticed by observationthat this product was not as smooth or as round as the products ofExample 1 and Example 2.

TABLE 2 Results of CAMSIZER ® measurements of Example 9 Screen ASTMWeight Percent Weight Percent Size (mm) Screen Size Retained on ScreenPassing >4.00  >#5   1.69 100 3.35  #6 3.73 98.31 2.80  #7 7.05 94.582.36  #8 10.79 87.53 2.00 #10 14.16 76.74 1.70 #12 15.68 62.58 1.40 #1417.86 46.90 1.18 #16 12.14 29.04 1.00 #18 7.46 16.90 0.85 #20 4.12 9.440.71 #25 2.28 5.32 <0.71 3.04 3.04

Example 10

Poultry litter from a poultry house in Russellville, Ala. was milled topass a 4.76 mm ( 3/16 inch) screen. This poultry litter was de-cakedevery six weeks and then a total cleanout after a year which is whenthis litter was collected. The moisture of the litter was 27%. Theprocedures for the acidifying steps were done like described in Example1 with the following noted differences.

Step 1: Acidifying Step

A SS Unijet 6500033 spray nozzle was used for applying the sulfuric acidwhich streamed instead of spraying. 0.382 kg (0.84 pounds) of 98%sulfuric acid was streamed onto 0.68 kg (1.5 pounds) of litter.

Step 2: Ammoniating Step

Ammonia was sparged into the small batch from Step 1 until the apparentpH was 6.0. No water was added during this ammoniating step. Due to theacid being streamed into the material instead of sprayed, largeagglomerates formed and the inside of these granules had a very low pHshowing incompleteness of the reaction of sulfuric acid with theammonia. The agglomerates were too large because of excessive liquidattractions between particles.

Example 11

The same prepared litter used for Example 10 was used for this example.The procedures for the acidifying steps were done like described inExample 1 with the following noted differences.

Step 1: Acidifying Step

A SS Unijet 11001 spray nozzle was used for applying the sulfuric acidwhich streamed instead of spraying. 0.126 kg (0.278 pounds) of 98%sulfuric acid was streamed onto 0.68 kg (1.5 pounds) of litter.

Step 2: Ammoniating Step

Ammonia was sparged into the small batch from Step 1 until the apparentpH was 6.0. No water was added during this ammoniating step. Largeagglomerates formed and the inside of these granules had a very low pHshowing incompleteness of the reaction of sulfuric acid with theammonia.

Step 3: Acidifying Step

0.165 kg (0.364 pounds) of 98% sulfuric acid was streamed onto 0.68 kg(1.5 pounds) of litter.

Step 2: Ammoniating Step

Ammonia was sparged into the small batch from Step 3 and the pH wouldnot raise to the targeted pH of 5.0-6.0. No water was added during thisammoniating step. There were a significant number of large agglomerates.

Example 12

The same prepared litter used for Example 10 was used for this example.The procedures for the acidifying steps were done like described inExample 1 with the following noted differences.

Step 1: First Acidifying Step

A SS Unijet 11001 spray nozzle was used for applying the sulfuric acidand this produced a good spray pattern. 0.135 kg (0.297 pounds) of 98%sulfuric acid was sprayed on the first 0.68 kg (1.5 pounds) of litterand 0.108 kg (0.0.238 pounds) of 98% sulfuric acid was sprayed on asecond 0.68 kg (1.5 pounds) of litter.

Step 2: First Ammoniating Step

Ammonia was sparged into the combined batches from Step 1 until theapparent pH was 7.0. No water was added during this ammoniating step.The final moisture was 19.3%.

Step 3: Second Acidifying Step

0.085 kg (0.187 pounds) of 98% sulfuric acid was sprayed on half of thematerial from Step 2 and 0.0986 kg (0.217 pounds) of 98% sulfuric acidwas sprayed on the second half of the material from Step 2.

Step 4: Second Ammoniating Step

Ammonia was sparged into the combined batches from Step 3 until theapparent pH was 6.5. No water was added during this ammoniating step andthe final moisture was 13.4%

Step 5: Third Acidifying Step

0.0909 kg (0.200 pounds) of 98% sulfuric acid was sprayed on half of thematerial from Step 4 and 0.101 kg (0.222 pounds) of 98% sulfuric acidwas sprayed on the second half of the material from Step 4.

Step 6: Third Ammoniating Step

Ammonia was sparged into the combined batches from Step 5 until theactual pH was 6.5. The water added during this ammoniating step was0.137 kg (0.301 pounds) and the moisture of the final product was 13.8%.

The products from Examples 5, 6, and 7 were combined together and runthrough a California Pellet mill with a 6.35 mm (¼ inch) die installed.The resulting product was a hard pellet about 6.35 mm in diameter and9.25 mm long. This product could be crumbled to a smaller size ifdesired.

Selected products were tested for carbon content and nutrient content.The results of these tests are shown in Table 3 below.

TABLE 3 Product Nutrient Analysis of Examples 1, 2, 3, 4, and PelletizedProduct Pelletized Product of Example Example Example Example ExamplesNutrient #1 #2 #3 #4 5, 6, & 7 % N 10.4 10.2 9.08 9.45 9.62 % P₂O₅ 2.011.79 2.13 2.22 2.35 % K₂O 1.43 1.39 1.72 1.60 1.80 % S 11.47 11.23 10.179.55 10.20 % Zn 0.024 0.360 0.026 0.034 0.028 % Mg 0.332 0.309 0.3580.360 0.383 % Ca 1.55 1.32 1.59 1.80 1.75 % Fe 0.116 0.107 0.112 0.1610.182 % Al 0.185 0.173 0.167 0.181 0.215 % Mn 0.026 0.024 0.028 0.0270.031 % Mo 0 0.002 0 0.002 0.002 % B 0.001 0.001 0.002 0.002 0.002 % Cu0.008 0.007 0.009 0.010 0.011 % C 15.8 14.3 *NM *NM *NM *NM = notmeasured

Example 13

The inventive fertilizer was tested on turf grass and visually inspectedto see how it performed in comparison to plots fertilized with otherlawn fertilizers. For this example, plots that had Bermuda grass growingin them were marked off in a level field with stakes and string. Eachplot was 1.22 m by 2.44 m (4 feet by 8 feet). Each plot had a bufferzone of 30.5 cm (1 foot) between it and any adjoining plot. Thefertilizers used for the plots were Scotts® Green Max Lawn Food (SG),see Table 4 for nutrient content; Meherrin Lawn and Garden Plant Food(MH), see Table 6 for nutrient content; and the inventive fertilizer ofExample 3 (E), see Table 3 for nutrient content. A baseline plot wasalso created for and no fertilizer was applied.

TABLE 4 Nutrient Content of SG Total N 27% Available Phosphate (P₂O₅) 0% Soluble Potash (K₂O)  2% Iron (Fe)  5% Sulfur (Mn) 10% Nutrientsderived from: Ammonium Sulfate, Methyleneureas, Urea, Potassium Sulfate,and Iron Sucrate; Contains 6.38% slowly available nitrogen frommethyleneureas.

The weight of fertilizer placed on each plot is listed below:

SG=48.4

MH=163.4

E=145.2

TABLE 5 Nutrients applied to each plot for Example 13 Test Weight Weightof Weight of Label of N (g) P₂O₅ (g) K₂O (g) SG 13.1 0 0.0968 MH 13.113.1 13.1 E 13.1 3.05 2.47 BL 0 0 0

Observations:

Because the weight of the SG required to balance the nitrogenapplication of the inventive fertilizer was much lower, it was difficultto spread the fertilizer evenly over the whole plot. Therefore, therewere spots in the turf grass of that plot that were greener than inother plots.

The plots receiving the inventive fertilizer, E, appeared to green asquickly as the SG plots but the greening was evenly distributed over thewhole plot.

All of the plots receiving fertilizers were greener than the BL plot.

The green for the plots that received the inventive fertilizer lasted aslong as the green for the SG plot and both of these lasted longer thanthe MH plot.

Conclusions from Example 13

The inventive fertilizer performed as well as the other fertilizers whenused on turf grass without any additional phosphate or potassium.

Example 14

To test the effects of the inventive fertilizer product on plant growth,cotton was grown in a greenhouse using 18.9 L (5 gallon) containers.Each container was prepared with 30 kg of local top soil that had beensieved to remove large rocks and other debris. Two cotton seeds wereplanted in each container and fertilizer was applied to each container.The baseline test (BL) was given no fertilizer. The E+ tests were giventhe inventive fertilizer and additional phosphate and potassium in thesecond fertilizer application at levels to match the inorganic phosphateand potassium in the test fertilizers purchased for comparison (MH andHY). The cotton seeds planted in each container were weighed to fallwithin the range of 0.0895 g to 0.1035 g. Each fertilizer applicationand the baseline were tested in triplicate. After the cotton plantssprouted, the containers were thinned to one plant per container.

The fertilizers used for Example 14 were Meherrin Lawn and Garden PlantFood (MH), Hi-Yield Growers Choice (HY), and Inventive FertilizerExample #3 (with nutrient levels shown in Table 3 above). The nutrientlevels of the MH and HY are listed in Table 6 and Table 7 below. Thetests given the inventive fertilizer were noted as E (given no extraphosphate or potassium) and E+(given additional phosphate and potassiumto balance the amount of each given per container for the MH and the HYfertilizers.

TABLE 6 Nutrient Content of MH Total N 8.00% Available Phosphate (P₂O₅)8.00% Soluble Potash (K₂O) 8.00% Nutrients derived from: AmmoniumSulfate, Muriate of Potash, Diammonium Phosphate, Urea

TABLE 7 Nutrient Content of HY Total N 12% Available Phosphate (P₂O₅) 6% Soluble Potash (K₂O)  6% Boron (B)  0.02% Copper (Cu)  0.05% Iron(Fe)  0.10% Manganese (Mn)  0.05% Zinc (Zn)  0.05% Nutrients derivedfrom: Nitrate of Potash, Ammoniated Phosphate, Urea, Polymer CoatedSulfur Coated Urea, Sodium Borate, Copper Sulfate, Ferrous Sulfate,Manganese Sulfate, Zinc Sulfate, 6.8% slowly available nitrogen fromPolymer Coated Sulfur Coated Urea

Table 8 shows how much fertilizer and other nutrients were given to eachcontainer for each test and Table 8b shows how much of each nutrient wasgiven to each container before planting.

TABLE 8 Amount of Fertilizer Applied per Container before planting forExample 14. Weight of Weight of Triple Potassium Weight of SuperChloride (0- Weight of Urea (46- Phosphate (0- 0-60) Fertilizer 0-0)Applied 45-0) Applied Applied to Test Applied to Balance to BalanceBalance Label (g) Nitrogen (g) Phosphate (g) K₂O (g) MH 1.53 0.27 0 0 HY2.00 0 0 0 E 2.73 0 0 0 E+ 2.73 0 0.14 0.14 *BL 0 0 0 0

TABLE 8b Weight of Nutrients Applied per Container for the Weights Shownin Table 8 Above Test Weight of Weight of Weight of Label N (g) P₂O₅ (g)K₂O (g) MH 0.24 0.12 0.12 HY 0.24 0.12 0.12 E 0.24 0.057 0.046 E+ 0.240.12 0.12 *BL 0 0 0

The containers were planted on Jun. 26, 2019. The containers werewatered regularly with equal weights amounts of rain water.

Additional fertilizer was applied to each container on Aug. 23, 2019 inthe amounts shown in Table 9. Table 9b shows the amount of each nutrientwas given to each container on Aug. 23, 2019.

TABLE 9 Amount of Fertilizer Applied per Container given to Example 14on Aug. 23, 2019 Weight Weight of Weight of of Urea Triple SuperPotassium Weight of Applied to Phosphate Chloride Fertilizer BalanceApplied to Applied to Test Applied Nitrogen Balance Balance Label (g)(g) Phosphate (g) K₂O (g) MH 3.22 0.56 0 0 HY 4.29 0 0 0 E 5.83 0 0 0 E+5.83 0 0.57 0.43 *BL 0 0 0 0

TABLE 9b Weight of Nutrients Applied per Container for the Weights Shownin Table 9 Above Weight of Weight of Weight of Test Label N (g) P₂O₅ (g)K₂O (g) MH 0.52 0.28 0.28 HY 0.51 0.26 0.26 E 0.52 0.12 0.099 E+ 0.520.37 0.36 BL 0 0 0

Due to low light and the late planting of the cotton, the plants beganto slow their growth and pests became a problem in the greenhouse. OnDec. 9, 2019, all of the plants were cut at the surface of the soil anddried in a 50° C. oven for 2 days and then weighed. The resultingaverages of the weights are provided in Table 10.

TABLE 10 Average Total Dry Weight of Cotton Plants for Example 14Average Dry % Difference Between Average Test Weight of Dry Weight andAverage Label Plants (g) Baseline Weight MH 37.0 +27.6% HY 37.4 +29.0% E32.3 +11.4% E+ 38.2 +31.8% BL 29.0     0%

Conclusions for Example 14

The inventive fertilizer improved plant growth.

The cotton plants given the inventive fertilizer with phosphate andpotassium levels to match the inorganic fertilizers produced healthierplants with more plant growth than any of the other tests. Additionalphosphate and potassium needed by a crop can be incorporated into theinventive fertilizer by the inventive process.

The plants grown with the inventive fertilizer produced up to a 32%increase in plant mass as compared to the plants grown without anyfertilizer.

The invention claimed is:
 1. A method for producing a poultrylitter-based fertilizer having an enhanced nitrogen level, enhancedratio of nitrogen to phosphorous, and increased sulfur level comprising:a) supplying poultry litter to a rotating rotary drum; b) adding acidand/or a source of acid to the rotating rotary drum, wherein the sourceof acid forms acid in the rotating rotary drum, and the acid in therotating rotary drum reacts with the poultry litter to form heat and anacidified mixture; c) adding water and at least one of ammonia or asource of ammonia to the rotating rotary drum, wherein the source ofammonia forms ammonia in the rotating rotary drum, and the ammonia inthe rotating rotary drum reacts with the acidified mixture to produceheat and an ammoniated mixture containing an ammonium salt; d) dryingand cooling the ammoniated mixture by evaporation of water to form adried, cooled product in a free-flowing semi-solid or solid form; e)repeating steps b) through d) until a desired nitrogen content isreached in the dried, cooled product, wherein in steps c) and d) anammonium salt layer is formed on a surface of the product, and whereinthe water added in a subsequent step c) is added in an amount to breakthe ammonium salt layer and allow ammonia to enter the product; f)adjusting a pH in at least one step b) to destroy pathogens, weed seeds,drugs, hormones, and/or antibiotics present in the poultry litter; g)collecting a waste stream from any step or wash down water, wherein atleast a portion of the waste stream is added to any of the steps b), c)and/or d), except for a last pass of steps c) and d); and h) finaldrying and cooling of the dried, cooled product to form granules of thepoultry litter-based fertilizer having an enhanced nitrogen levelgreater than 6% nitrogen by weight based on the total weight of thepoultry litter-based fertilizer, an enhanced ratio of nitrogen tophosphorous, and increased sulfur level compared to a poultry-basedfertilizer produced by only running steps b) and c) once.
 2. The methodaccording to claim 1, wherein no heat generated by burning fossil fuelsis added to the method.
 3. The method according to claim 1, wherein theacid and/or source of acid in step b) comprises one or more selectedfrom the group of sulfuric acid (H₂SO₄), sulfurous acid (H₂SO₃), nitricacid (HNO₃), nitrous acid (HNO₂), phosphoric acid (H₃PO₄), phosphorousacid (H₃PO₃), hypophosphorus acid (H₃PO₂), pyrophosphoric acid H₄P₂O₇,triphosphoric acid (H₅P₃O₁₀), trimetaphosphoric acid (H₃P₃O₉), andhypophosphoric acid (H₄P₂O₆), sulfur trioxide, and/or oleum.
 4. Themethod according to claim 1, wherein the acid and/or source of acid instep b) is sulfuric acid and/or oleum and partially carbonizes thepoultry litter and/or converts lignocellulose to forms of carbon morereadily available to soil organisms and/or plants.
 5. The methodaccording to claim 1, further comprising: adding at least one secondarynutrient and/or micronutrient, wherein at least one secondary nutrientand/or micronutrient is subjected to at least one acidifying step b);wherein the at least one secondary nutrient and/or micronutrientcomprises at least one metal, metal oxide or a mixture of a metal and ametal oxide; wherein the metal comprises at least one metal chosen fromthe group of zinc, iron, copper, magnesium, manganese, and/or nickel;and wherein the metal oxide comprises at least one metal oxide chosenfrom the group of zinc oxide, magnesium oxide, manganese oxides, copperoxides, and/or iron oxides; and/or wherein the at least one secondarynutrient and/or micronutrient comprises at least one of lime, magnesiumchloride, magnesium nitrate, sodium nitrate, sodium chloride, zincchloride, zinc nitrate, copper chloride, copper nitrate, potassiumchloride, potassium nitrate, potassium sulfate, triple super phosphate,and/or super phosphate; and/or wherein the at least one secondarynutrient and/or micronutrient comprises at least one of potassiumhydroxide, zinc hydroxide, magnesium hydroxide, or manganese hydroxide.6. The method according to claim 5, wherein the at least one secondarynutrient and/or micronutrient forms a sulfate.
 7. The method accordingto claim 1, wherein the method is a closed-system and mainly water vaporand the poultry litter-based fertilizer are expelled from the methodwith any waste streams being recycled into any of the steps.
 8. Themethod according to claim 1, wherein the poultry litter-based fertilizercontains % N levels greater than 8 wt. %; % P₂O₅ levels of less than 2wt. %; % K₂O levels of more than 2 wt. %; and % S levels of greater than5 wt %.
 9. The method according to claim 1, wherein the acidifiedmaterial in step b) comprises less than 40 wt % water.
 10. The methodaccording to claim 1, wherein the heat generated in steps b) and/or c)raises a temperature of the ammoniated mixture in step c) to greaterthan 90° C.
 11. The method according to claim 1, wherein in the step d)the ammoniated mixture is cooled to less than 80° C.
 12. The methodaccording to claim 1, wherein the poultry litter-based fertilizercomprises less than 12 wt % water.
 13. The method according to claim 1,wherein the acid and/or the source of acid is added in the rotatingrotary drum in an amount to provide the acidified material with a pH ofless than
 1. 14. The method according to claim 1, wherein the ammoniaand/or the source of ammonia is added to the rotating rotary drum in anamount to provide the ammoniated material with a pH of at least
 5. 15.The method according to claim 1, wherein the rotating rotary drumcomprises a first chamber, a second chamber and a third chamber incommunication with each other, the step b) is conducted in the firstchamber, the step c) is conducted in the second chamber and the step d)is conducted in the third chamber, wherein the method is operated incontinuous manner with the materials flowing continuously from the firstchamber, to the second chamber and then to the third chamber.
 16. Themethod according to claim 15, further comprising providing a continuousair flow through the first chamber, the second chamber and the thirdchamber wherein air flow exiting the rotating rotary drum is sent to ascrubber to form a waste stream that is fed back to any of the firstchamber, the second chamber and/or the third chamber.
 17. The methodaccording to claim 15, wherein the rotating rotary drum is rotated sothat the litter being acidified is tumbled in the first chamber, theacidified mixture being ammoniated is tumbled in the second chamber, andthe ammoniated material being dried and cooled is raised and thendropped through the third chamber.
 18. The method according to claim 17,wherein water is sprayed in the first chamber, the second chamber andthe third chamber.
 19. The method according to claim 17, furthercomprising providing a constant air flow through the dropping materialsin the third chamber.
 20. The method according to claim 15, wherein instep b) the acid and/or the source of acid is sprayed on the littertumbling against the first chamber of the rotating rotary drum, in stepc) the water is sprayed on the acidified mixture tumbling against thesecond chamber of the rotating rotary drum, and the ammonia and/orsource of ammonia is injected into the tumbling acidified mixture, andin step d) the drying and cooling is increased by raising and droppingthe ammoniated product in the third chamber of the rotating rotary drum.21. The method according to claim 1, wherein the poultry litter-basedfertilizer comprising at least 10% bedding material by weight from thepoultry litter.
 22. The method according to claim 1, wherein the poultrylitter-based fertilizer comprising at least 4.5% by weight of othernutrients, secondary nutrients, and micronutrients wherein at least 0.5%by weight of the nutrients, secondary nutrients, and micronutrients arefrom inorganic sources.
 23. The method according to claim 1, wherein thepoultry litter-based fertilizer having a granule size of 1 mm to 3 mmand wherein the crush strength of the granule is at least 4.45 Newtons.24. A method for producing a poultry litter-based fertilizer having anenhanced nitrogen level, enhanced ratio of nitrogen to phosphorous, andincreased sulfur level comprising: a) supplying poultry litter to arotating rotary drum; b) adding acid and/or a source of acid to therotating rotary drum, wherein the source of acid forms acid in therotating rotary drum, and the acid in the rotating rotary drum reactswith the poultry litter to form heat and an acidified mixture; c) addingwater and at least one of ammonia or a source of ammonia to the rotatingrotary drum, wherein the source of ammonia forms ammonia in the rotatingrotary drum, and the ammonia in the rotating rotary drum reacts with theacidified mixture to produce heat and an ammoniated mixture containingan ammonium salt; d) drying and cooling the ammoniated mixture byevaporation of water to form a dried, cooled product in a free-flowingsemi-solid or solid form, wherein in step c) the water is added in anamount to prevent an ammonium salt layer from forming on the dried,cooled product; e) repeating steps b) through d) until a desirednitrogen content is reached in the dried, cooled product; f) adjusting apH in at least one step b) to destroy pathogens, weed seeds, drugs,hormones, and/or antibiotics present in the poultry litter; g)collecting a waste stream from any step or wash down water, wherein atleast a portion of the waste stream is added to any of the steps b), c)and/or d), except for a last pass of steps c) and d); and h) finaldrying and cooling of the dried, cooled product to form granules of thepoultry litter-based fertilizer having an enhanced nitrogen levelgreater than 6% nitrogen by weight based on the total weight of thepoultry litter-based fertilizer, an enhanced ratio of nitrogen tophosphorous, and increased sulfur level compared to a poultry-basedfertilizer produced by only running steps b) and c) once.
 25. The methodaccording to claim 24, wherein no heat generated by burning fossil fuelsis added to the method.
 26. The method according to claim 24, whereinthe acid and/or source of acid in step b) comprises one or more selectedfrom the group of sulfuric acid (H₂SO₄), sulfurous acid (H₂SO₃), nitricacid (HNO₃), nitrous acid (HNO₂), phosphoric acid (H₃PO₄), phosphorousacid (H₃PO₃), hypophosphorus acid (H₃PO₂), pyrophosphoric acid H₄P₂O₇,triphosphoric acid (H₅P₃O₁₀), trimetaphosphoric acid (H₃P₃O₉), andhypophosphoric acid (H₄P₂O₆), sulfur trioxide, and/or oleum.
 27. Themethod according to claim 24, wherein the acid and/or source of acid instep b) is sulfuric acid and/or oleum and partially carbonizes thepoultry litter and/or converts lignocellulose to forms of carbon morereadily available to soil organisms and/or plants.
 28. The methodaccording to claim 24, further comprising: adding at least one secondarynutrient and/or micronutrient, wherein at least one secondary nutrientand/or micronutrient is subjected to at least one acidifying step b);wherein the at least one secondary nutrient and/or micronutrientcomprises at least one metal, metal oxide or a mixture of a metal and ametal oxide; wherein the metal comprises at least one metal chosen fromthe group of zinc, iron, copper, magnesium, manganese, and/or nickel;and wherein the metal oxide comprises at least one metal oxide chosenfrom the group of zinc oxide, magnesium oxide, manganese oxides, copperoxides, and/or iron oxides; and/or wherein the at least one secondarynutrient and/or micronutrient comprises at least one of lime, magnesiumchloride, magnesium nitrate, sodium nitrate, sodium chloride, zincchloride, zinc nitrate, copper chloride, copper nitrate, potassiumchloride, potassium nitrate, potassium sulfate, triple super phosphate,and/or super phosphate; and/or wherein the at least one secondarynutrient and/or micronutrient comprises at least one of potassiumhydroxide, zinc hydroxide, magnesium hydroxide, or manganese hydroxide.29. The method according to claim 28, wherein the at least one secondarynutrient and/or micronutrient forms a sulfate.
 30. The method accordingto claim 24, wherein the method is a closed-system and mainly watervapor and the poultry litter-based fertilizer are expelled from themethod with any waste streams being recycled into any of the steps. 31.The method according to claim 24, wherein the poultry litter-basedfertilizer contains % N levels greater than 8 wt. %; % P₂O₅ levels ofless than 2 wt. %; % K₂O levels of more than 2 wt. %; and % S levels ofgreater than 5 wt %.
 32. The method according to claim 24, wherein theacidified material in step b) comprises less than 40 wt % water.
 33. Themethod according to claim 24, wherein the heat generated in steps b)and/or c) raises a temperature of the ammoniated mixture in step c) togreater than 90° C.
 34. The method according to claim 24, wherein in thestep d) the ammoniated mixture is cooled to less than 80° C.
 35. Themethod according to claim 24, wherein the poultry litter-basedfertilizer comprises less than 12 wt % water.
 36. The method accordingto claim 24, wherein the acid and/or the source of acid is added in therotating rotary drum in an amount to provide the acidified material witha pH of less than
 1. 37. The method according to claim 24, wherein theammonia and/or the source of ammonia is added to the rotating rotarydrum in an amount to provide the ammoniated material with a pH of atleast
 5. 38. The method according to claim 24, wherein the rotatingrotary drum comprises a first chamber, a second chamber and a thirdchamber in communication with each other, the step b) is conducted inthe first chamber, the step c) is conducted in the second chamber andthe step d) is conducted in the third chamber, wherein the method isoperated in continuous manner with the materials flowing continuouslyfrom the first chamber, to the second chamber and then to the thirdchamber.
 39. The method according to claim 38, further comprisingproviding a continuous air flow through the first chamber, the secondchamber and the third chamber wherein air flow exiting the rotatingrotary drum is sent to a scrubber to form a waste stream that is fedback to any of the first chamber, the second chamber and/or the thirdchamber.
 40. The method according to claim 38, wherein the rotatingrotary drum is rotated so that the litter being acidified is tumbled inthe first chamber, the acidified mixture being ammoniated is tumbled inthe second chamber, and the ammoniated material being dried and cooledis raised and then dropped through the third chamber.
 41. The methodaccording to claim 40, wherein water is sprayed in the first chamber,the second chamber and the third chamber.
 42. The method according toclaim 40, further comprising providing a constant air flow through thedropping materials in the third chamber.
 43. The method according toclaim 38, wherein in step b) the acid and/or the source of acid issprayed on the litter tumbling against the first chamber of the rotatingrotary drum, in step c) the water is sprayed on the acidified mixturetumbling against the second chamber of the rotating rotary drum, and theammonia and/or source of ammonia is injected into the tumbling acidifiedmixture, and in step d) the drying and cooling is increased by raisingand dropping the ammoniated product in the third chamber of the rotatingrotary drum.
 44. The method according to claim 24, wherein the poultrylitter-based fertilizer comprising at least 10% bedding material byweight from the poultry litter.
 45. The method according to claim 24,wherein the poultry litter-based fertilizer comprising at least 4.5% byweight of other nutrients, secondary nutrients, and micronutrientswherein at least 0.5% by weight of the nutrients, secondary nutrients,and micronutrients are from inorganic sources.
 46. The method accordingto claim 24, wherein the poultry litter-based fertilizer having agranule size of 1 mm to 3 mm and wherein the crush strength of thegranule is at least 4.45 Newtons.
 47. A method for producing a poultrylitter-based fertilizer having an enhanced nitrogen level, enhancedratio of nitrogen to phosphorous, and increased sulfur level comprising:a) supplying poultry litter to a rotating rotary drum; b) adding acidand/or a source of acid to the rotating rotary drum, wherein the sourceof acid forms acid in the rotating rotary drum, and the acid in therotating rotary drum reacts with the poultry litter to form heat and anacidified mixture; c) adding water and at least one of ammonia or asource of ammonia to the rotating rotary drum, wherein the source ofammonia forms ammonia in the rotating rotary drum, and the ammonia inthe rotating rotary drum reacts with the acidified mixture to produceheat and an ammoniated mixture containing an ammonium salt; d) dryingand cooling the ammoniated mixture by evaporation of water to form adried, cooled product in a free-flowing semi-solid or solid form; e)repeating steps b) through d) until a desired nitrogen content isreached in the dried, cooled product; f) adjusting a pH in at least onestep b) to destroy pathogens, weed seeds, drugs, hormones, and/orantibiotics present in the poultry litter; and final drying and coolingof the dried, cooled product to form the poultry litter-based fertilizerhaving an enhanced nitrogen level, enhanced ratio of nitrogen tophosphorous, and increased sulfur level compared to a poultry-basedfertilizer produced by only running steps b) and c) once, wherein thepoultry litter-based fertilizer comprises: at least 8% nitrogen byweight; at least 30% ammonium sulfate by weight; at least 0.91%potassium by weight; at least 9% sulfur by weight; and at least 2.5%total other nutrients, secondary nutrients, and micronutrients byweight, based on the total weight of the poultry litter-basedfertilizer.
 48. A method for producing a poultry litter-based fertilizerhaving an enhanced nitrogen level, enhanced ratio of nitrogen tophosphorous, and increased sulfur level comprising: a) supplying poultrylitter to a rotating rotary drum; b) adding acid and/or a source of acidto the rotating rotary drum, wherein the source of acid forms acid inthe rotating rotary drum, and the acid in the rotating rotary drumreacts with the poultry litter to form heat and an acidified mixture; c)adding water and at least one of ammonia or a source of ammonia to therotating rotary drum, wherein the source of ammonia forms ammonia in therotating rotary drum, and the ammonia in the rotating rotary drum reactswith the acidified mixture to produce heat and an ammoniated mixturecontaining an ammonium salt; d) drying and cooling the ammoniatedmixture by evaporation of water to form a dried, cooled product in afree-flowing semi-solid or solid form; e) repeating steps b) through d)until a desired nitrogen content is reached in the dried, cooledproduct; f) adjusting a pH in at least one step b) to destroy pathogens,weed seeds, drugs, hormones, and/or antibiotics present in the poultrylitter; and final drying and cooling of the dried, cooled product toform the poultry litter-based fertilizer having an enhanced nitrogenlevel, enhanced ratio of nitrogen to phosphorous, and increased sulfurlevel compared to a poultry-based fertilizer produced by only runningsteps b) and c) once, wherein the poultry litter-based fertilizercomprising at least 40% ammonium sulfate by weight.